e10vk
UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Form 10-K
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
For the fiscal year ended December 31, 2006
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from to
Commission File Number 000-50132
Sterling Chemicals, Inc.
(Exact name of registrant as specified in its charter)
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Delaware
(State or other jurisdiction of
incorporation or organization)
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76-0502785
(I.R.S. Employer Identification No.) |
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333 Clay Street, Suite 3600
Houston, Texas 77002-4109
(Address of principal executive offices)
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(713-650-3700)
(Registrants telephone number,
including area code) |
Securities registered pursuant to Section 12(b) of the Act: None
Securities registered pursuant to Section 12(g) of the Act:
Common Stock, par value $.01 per share
(Title of class)
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in
Rule 405 of the Securities Act. Yes
o No þ.
Indicate by check mark if the registrant is not required to file reports pursuant to Section
13 of Section 15(d) of the Act. Yes
o No þ.
Indicate by check mark whether the registrant (1) has filed all reports required to be filed
by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or
for such shorter period that the registrant was required to file such reports) and (2) has been
subject to such filing requirements for the past 90 days. Yes þ No o.
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation
S-K is not contained herein and will not be contained, to the best of the registrants knowledge,
in definitive proxy or information statements incorporated by reference in Part III of this Form
10-K or any amendment to this Form 10-K. o.
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated
filer, or a non-accelerated filer. See definition of accelerated filer and large accelerated
filer in Rule 12b-2 of the Exchange Act. (Check one):
Large accelerated filer o Accelerated filer o Non-accelerated filer þ
The aggregate market value of the registrants common stock, par value $.01 per share, held by
non-affiliates at June 30, 2006 (the last business day of the registrants most recently completed
second fiscal quarter), based upon the value of the last sales price of these shares as reported on
the OTC Electronic Bulletin Board maintained by the National Association of Securities Dealers,
Inc., was $18,459,803.
APPLICABLE ONLY TO REGISTRANTS INVOLVED IN BANKRUPTCY PROCEEDINGS DURING THE PRECEDING FIVE YEARS:
Indicate by check mark whether the registrant has filed all documents and reports required to
be filed by Section 12, 13 or 15(d) of the Securities Exchange Act of 1934 subsequent to the
distribution of securities under a plan confirmed by a court. Yes þ No o.
Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of
the Exchange Act). Yes o No
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As of February 28, 2007, Sterling Chemicals, Inc. had 2,828,460 shares of common stock
outstanding.
Portions of the definitive Proxy Statement relating to the 2007 Annual Meeting of Stockholders
of Sterling Chemicals, Inc. are incorporated by reference in Part III of this Form 10-K.
IMPORTANT INFORMATION REGARDING THIS FORM 10-K
Unless otherwise indicated, references to we, us, our and ours in this Form 10-K refer
collectively to Sterling Chemicals, Inc. and its wholly-owned subsidiaries.
Readers should consider the following information as they review this Form 10-K.
Forward-Looking Statements
This report contains forward-looking statements within the meaning of Section 27A of the
Securities Act and Section 21E of the United States Securities Exchange Act of 1934, as amended
(the Exchange Act). Forward-looking statements give our current expectations or forecasts of
future events. All statements other than statements of historical fact are, or may be deemed to be,
forward-looking statements. Such statements include, without limitation, any statement that may
project, indicate or imply future results, events, performance or achievements, and may contain or
be identified by the words expect, intend, plan, predict, anticipate, estimate,
believe, should, could, may, might, will, will be, will continue, will likely
result, project, forecast, budget and similar expressions. Statements in this report that
contain forward-looking statements include, but are not limited to, information concerning our
possible or assumed future results of operations. While our management considers these expectations
and assumptions to be reasonable, they are inherently subject to significant business, economic,
competitive, regulatory and other risks, contingencies and uncertainties, most of which are
difficult to predict and many of which are beyond our control. We disclose important factors that
could cause our actual results to differ materially from our expectations under Risk Factors,
Managements Discussion and Analysis of Financial Condition and Results of Operations and
elsewhere in this report. These risks, contingencies and uncertainties relate to, among other
matters, the following:
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the cyclicality of the petrochemicals industry; |
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current and future market and industry conditions and their effect on our
results of operations or financial position; |
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the extent, timing and impact of expansions of production capacity of our
products, by us or by our competitors; |
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the potential effects of market and industry conditions and cyclicality on our
competitiveness, business strategy, results of operations or financial position; |
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the adequacy of our liquidity and availability of financing; |
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our environmental management programs and safety initiatives; |
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future uses of, and requirements for, financial resources; |
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future contractual obligations; |
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future amendments, renewals or terminations of existing contractual relationships; |
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business strategies; |
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growth opportunities; |
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competitive position; |
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expected financial position; |
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future cash flows, dividends or financing plans; |
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budgets for capital and other expenditures; |
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plans and objectives of management; |
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outcomes of legal proceedings; |
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our ability to renew our collective bargaining agreement; |
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compliance with applicable laws; |
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our reliance on marketing partners; |
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adequacy of insurance coverage or indemnification rights; |
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the timing or extent of changes in commodity prices for our products or raw materials; |
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petrochemicals industry production capacity or operating rates; |
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increases in the cost of, or our ability to obtain, raw materials or energy; |
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regulatory initiatives and compliance with governmental laws or regulations,
including environmental laws or regulations; |
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customer preferences; |
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our ability to attract or retain high quality employees; |
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operating hazards attendant to the petrochemicals industry; |
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casualty losses, including those resulting from weather related events; |
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changes in foreign, political, social or economic conditions; |
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risks of war, military operations, other armed hostilities, terrorist acts or embargoes; |
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changes in technology that could require significant capital expenditures in
order to maintain competitiveness or could cause existing manufacturing processes
to become obsolete; |
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effects of litigation; |
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cost, availability or adequacy of insurance; and |
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various other matters, many of which are beyond our control. |
The risks included here are not exhaustive. Other sections of this report, and our other
filings with the Securities and Exchange Commission, include additional factors that could
adversely affect our business, results of operations or financial performance. See Risk Factors
contained in Item 1A of Part I of this Form 10-K. Given these risks and uncertainties, investors
should not place undue reliance on forward-looking statements. Forward-looking statements included
in this Form 10-K are made only as of the date of this Form 10-K and are not guarantees of future
performance. Although we believe that the expectations reflected in these forward-looking
statements are reasonable, such expectations may prove to have been incorrect. All written or oral
forward-looking statements attributable to us, or persons acting on our behalf, are expressly
qualified in their entirety by these cautionary statements.
Document Summaries
Descriptions of documents and agreements contained in this Form 10-K are provided in summary
form only, and such summaries are qualified in their entirety by reference to the actual documents
and agreements filed as exhibits to this Form 10-K.
Fiscal Year
In December 2002, we changed our fiscal year-end from September 30 to December 31.
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PART I
Item 1. Business
We are a leading North American producer of selected petrochemicals used to manufacture a wide
array of consumer goods and industrial products throughout the world. Our primary products are
acetic acid, styrene and plasticizers.
Our acetic acid is used primarily to manufacture vinyl acetate monomer, which is used in a
variety of products, including adhesives and surface coatings. All of our acetic acid production
is sold to BP Amoco Chemical Company (BP Chemicals), and we are BP Chemicals sole source of
acetic acid production in the Americas. We sell our acetic acid to BP Chemicals pursuant to a
long-term contract (Production Agreement) that extends until 2016. The Production Agreement
provides us with a portion of the profits derived from BP Chemicals sales of the acetic acid we
produce and reimbursement of 100% of our fixed and variable costs of acetic acid production. This
Production Agreement has provided us with a steadily increasing source of income since the
inception of this relationship in 1986 and, over the last three years, we have operated at over
100% of capacity and at utilization rates greater than the industry average.
We believe we have one of the lowest cost acetic acid facilities in the world. Our acetic
acid facility utilizes BP Chemicals proprietary carbonylation technology, or Cativa Technology,
which we believe offers several advantages over competing production methods, including lower
energy requirements and lower fixed and variable costs. We also jointly invest with BP Chemicals in
capital expenditures related to our acetic acid facility. Acetic acid production has two major raw
materials requirements methanol and carbon monoxide. BP Chemicals, a producer of methanol,
supplies 100% of our methanol requirements related to our production of acetic acid. All of the
carbon monoxide we use in the production of acetic acid is supplied by Praxair Hydrogen Supply,
Inc. (Praxair) from a partial oxidation unit constructed by Praxair on land leased from us at our
Texas City site.
Styrene is a commodity chemical used to produce intermediate products such as polystyrene,
expandable polystyrene resins and ABS plastics, which are used in a wide variety of products such
as household goods, foam cups and containers, disposable food service items, toys, packaging and
other consumer and industrial products. Approximately 30% to 40% of our styrene capacity is
currently committed for sales in North America under long-standing customer relationships. In
addition, approximately 30% to 40% of our styrene capacity is currently being used to produce
styrene sold on the spot market, with the balance of our capacity available to produce styrene for
sales throughout the world when market conditions warrant.
All of our plasticizers, which are used to make flexible plastics, such as shower curtains,
floor coverings, automotive parts and construction materials, are produced exclusively for BASF
Corporation (BASF) pursuant to a long-term production agreement that extends until 2013, subject
to some limited early termination rights held by BASF beginning in 2010. Under our agreement with
BASF, BASF provides us with most of the required raw materials, markets the plasticizers we
produce, and is obligated to make certain fixed quarterly payments to us and to reimburse us
monthly for our actual production costs and capital expenditures relating to our plasticizers
facility.
We manufacture all of our petrochemicals products at our site in Texas City, Texas. In terms
of production capacity, our Texas City site has the sixth largest acetic acid facility in the world
and the fourth largest styrene facility in North America. Our Texas City site, which covers an
area of 290 acres, is strategically located on Galveston Bay and benefits from a deep-water dock
capable of handling ships with up to a 40-foot draft, as well as four barge docks, direct access to
Union Pacific and Burlington Northern railways with in-motion rail scales on site, truck loading
racks and weigh scales, stainless and mild steel storage tanks, three waste deepwells, 135 acres of
available land zoned for heavy industrial use, additional land zoned for light industrial use and a
supportive political environment for growth. In addition, we are in the heart of one of the
largest petrochemical complexes on the Gulf Coast and, as a result, we have on-site access to a
number of key raw material pipelines and are in close proximity to a number of the larger refinery
complexes that provide some of our principal raw materials. Given our under-utilized
infrastructure, as well as ample unoccupied land, there are significant opportunities for further
development of our Texas City site.
We own the acetic acid, styrene and plasticizers manufacturing units located at our Texas City
site. We also lease a portion of our Texas City site to Praxair, who constructed a partial
oxidation unit on that land, and we lease a portion of our Texas City site to S&L Cogeneration
Company, a 50/50 joint venture between us and Praxair Energy Resources, Inc., who constructed a
cogeneration facility on that land. We lease the space for our principal offices located in
Houston, Texas.
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In addition to our intention to further expand the capacity of our acetic acid facility, we
are presently undertaking numerous initiatives to attract new chemical related businesses to our
Texas City site. Given our significant under-utilized infrastructure, land, materials handling,
utilities and storage, our Texas City site should be a favorable location for companies looking to
construct new manufacturing facilities on the Gulf Coast of the United States. We believe that the
construction of a new facility at our site by another company would lower the amount of fixed costs
allocated to each of our operating units and provide us with additional revenue. We are presently
undertaking numerous initiatives to attract new chemical related businesses to our Texas City site.
Specifically, we are seeking long-term contractual business arrangements or partnerships that will
provide us with an ability to realize the value of our under-utilized assets through profit sharing
or other revenue generating arrangements. For development projects that may have significant
capital expenditure requirements, we are considering joint ventures or other arrangements where we
would contribute certain of our assets and management expertise to minimize our share of the
capital costs.
Business Strategy
Grow Our Business. We intend to grow our acetic acid business through capacity expansions. We
intend to take advantage of recent investments in our acetic acid facility made by us and BP
Chemicals, which we believe have positioned our acetic acid facility for cost-effective future
capacity expansions at lower incremental cost. We currently have low-cost debottlenecking
opportunities which could increase annual capacity of the acetic acid facility by up to
approximately 7% to approximately 1.2 billion pounds. In addition, a new acetic acid reactor
installed in 2003, is capable of producing up to 1.7 billion pounds annually.
Our Texas City site offers approximately 135 acres for future expansion by us or by other
companies that can benefit from our existing infrastructure and facilities, and includes a
greenbelt around the northern edge of the plant site. Our Texas City site is strategically located
on Galveston Bay and we benefit from a deep-water dock capable of handling ships with up to a
40-foot draft, as well as four barge docks, direct access to Union Pacific and Burlington Northern
railways with in-motion rail scales on site, truck loading racks and weigh scales, stainless and
mild steel storage tanks, three waste deepwells, 135 acres of available land zoned for heavy
industrial use, additional land zoned for light industrial use and a supportive political
environment for growth. In addition, we are in the heart of one of the largest petrochemical
complexes on the Gulf Coast and, as a result, we have on-site access to a number of key raw
material pipelines and are in close proximity to a number of the larger refinery complexes that
provide some of our principal raw materials.
Given our under-utilized infrastructure, as well as ample unoccupied land, there are
significant opportunities for further development of our Texas City site. We believe that the
construction of a new facility at our site by another company would lower the amount of fixed costs
allocated to each of our operating units and provide us with additional revenue. We are presently
undertaking numerous initiatives to attract new chemical related businesses to our Texas City site.
Specifically, we are seeking long-term contractual business arrangements or partnerships that will
provide us with an ability to realize the value of our under-utilized assets through profit sharing
or other revenue generating arrangements. For development projects that may have significant
capital expenditure requirements, we are considering joint ventures or other arrangements where we
would contribute certain of our assets and management expertise to minimize our share of the
capital costs. We are currently exploring opportunities involving renewable fuels projects, a new
patented process for chemicals manufacturing from waste streams, chemicals terminalling and waste
injection well operations. In particular, we are currently in preliminary discussions with two
biodiesel producers with respect to several such potential arrangements.
We plan to evaluate strategic acquisitions, focusing on chemical businesses and assets which
would allow us to increase our market share of products we currently produce or those that would
provide upstream or downstream integration within our existing businesses.
We intend to continue operating our styrene facility while seeking strategic alternatives and
maintaining operational flexibility to capitalize on any upturns in the styrene industry. We have
the fourth largest styrene facility in North America, capable of producing 1.7 billion pounds
annually. Approximately 30% to 40% of our styrene capacity is currently committed for sales in
North America under long-standing customer relationships. In addition, approximately 30% to 40% of
our styrene capacity is currently being used to produce styrene sold on the spot market, with
the balance of our capacity available to produce styrene for sales when market conditions
warrant. Styrene and polystyrene industry participants, including The DOW Chemical Company and
NOVA Chemicals Corporation, have recently announced a desire to seek transactions which would
restructure the North American styrene and polystyrene industries, thereby improving the balance of
supply and demand in North America. According to Chemical Market Associates, Inc. (CMAI), if
demand for styrene remains steady, restructuring of North American styrene capacity should improve
production rates in North America and lead to improved industry profitability. Given our styrene
production capability and total uncontracted capacity, we are in a position to take advantage of
any restructuring of the styrene industry and to capitalize on any improvements in styrene market
conditions.
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Improve Organization Efficiency and Cost Structure. We continually seek to improve our cost
competitiveness through organizational efficiencies, productivity enhancements, operating controls
and general cost reductions. Since 2004, we have developed and implemented organizational
efficiency projects involving the design, development and implementation of uniform and
standardized systems, processes and policies to improve our production, maintenance, process
efficiency, logistics and materials management and procurement functions. During this period,
these projects reduced our fixed costs by more than $20 million, representing a 15% reduction in
our annual fixed costs. Approximately 10% to 15% of these cost savings accrue to the benefit of
some of our customers under the cost reimbursement provisions of our production agreements. We
believe the expansion of our acetic acid business, further development of our business and
acquisitions will lead to further cost efficiencies.
Industry Overview
Acetic Acid. The North American acetic acid industry is enjoying a period of sustained
domestic demand growth as well as substantial export demand. This has led to current North
American industry utilization rates of 86% and Tecnon OrbiChem, or Tecnon, projects utilization
rates to increase to over 98% by 2013. The North American acetic acid industry is inherently less
cyclical than many other petrochemical products due to a number of important features.
There are only four large producers of acetic acid in North America and historically these
producers have made capacity additions in a disciplined and incremental manner, primarily using
small expansion projects or exploiting debottlenecking opportunities. In addition, the leading
technology required to manufacture acetic acid is controlled by two global companies, which permits
these companies to control the pace of new capacity additions through the licensing or development
of such additional capacity. The limited availability of this technology also creates a
significant barrier to entry into our industry by potential competitors.
Global production capacity of acetic acid as of December 31, 2006 was approximately 24 billion
pounds per year, with current North American production capacity at approximately 7 billion pounds
per year. The North American acetic acid market is mature and well developed and is dominated by
four major producers that account for approximately 94% of the acetic acid production capacity in
North America. Demand for acetic acid is linked to the demand for vinyl acetate monomer, a key
intermediate in the production of a wide array of polymers. Vinyl acetate monomer is the largest
derivative of acetic acid, representing over 40% of global demand. According to Tecnon, annual
global production of vinyl acetate monomer is expected to increase from 10.4 billion pounds in 2005
to 12.2 billion pounds in 2010.
The North American acetic acid industry tends to sell most of its products through long-term
sales agreements having cost plus pricing mechanisms, eliminating much of the volatility seen in
other petrochemicals products and resulting in more stable and predictable earnings and profit
margins.
Several acetic acid capacity additions have occurred since 1998, including an expansion of our
acetic acid unit from 800 million pounds of rated annual production capacity to 1.1 billion pounds
during 2005. These capacity additions were somewhat offset by reductions of approximately 1.6
billion pounds in annual global capacity from the shutdown of various outdated acetic acid plants
from 1999 through 2001. In 2006, BP Chemicals closed two of its outdated acetic acid production
units in Hull, England that had a combined annual capacity of approximately 500 million pounds
(which had been sold primarily in Europe and South America). We and BP Chemicals are reviewing
further expansion of our acetic acid plant in 2008 or 2009.
Styrene. The North American styrene industry is currently in a protracted down cycle,
primarily as a result of over-supply. This shift is the result of two major developments. Export
demand has historically represented over 20% of North American production capacity. Regional cost
pressures in addition to new production capacity being added in Asia and the Middle East, have made
it difficult for North American producers to compete in these export markets on a continuous basis.
In addition, a significant amount of styrene capacity has been added globally over the past five
to ten years by producers of propylene oxide using so-called PO-SM technology, which produces
styrene as a co-product. Propylene oxide is a key intermediate in the production of polyurethane,
and polyurethane demand growth has been significantly greater than demand growth for styrene,
exacerbating the over-supply of styrene. During periods of over-supply, production rates for
styrene producers decrease significantly. Production rates in North America are currently
estimated by CMAI to be 75% of capacity. When production rates are low, unit production costs
increase due to the allocation of fixed costs over a lower production volume and a reduction in the
efficiency of the manufacturing unit, both in energy usage and in the conversion rates for raw
materials. Compounding these cost impacts, prices for the principal styrene raw materials, benzene
and ethylene, are currently near historical highs, putting pressure on margins on styrene sales
even though styrene contract prices are near historic highs. According to CMAI, benzene and
ethylene prices are expected to decline by approximately 8% and 7%, respectively, on average over
each of the next five years.
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Over the last five years, China has been the driver for growth in styrene demand, representing
approximately 75% of the worlds styrene demand growth in that period. Historically, we have
positioned ourselves to take advantage of peaks in the Asian styrene markets, with a large portion
of our styrene capacity not being committed under long-term arrangements. However, over the last
two years, relatively high benzene and domestic natural gas prices have significantly limited our
ability to sell styrene into the Asian markets, and high styrene prices have reduced styrene global
demand growth rates. In addition, several of our competitors have announced an intention to build
new styrene production units outside the United States, further complicating our ability to sell
styrene into the Asian markets. In 2006, our competitors added 2.6 billion pounds of new styrene
capacity in Asia. The majority of the remaining announced construction projects are scheduled to
start up between 2007 and 2009, although it is not uncommon for announced construction to be
delayed. For example, Shell Oil Company (Shell) and Saudi Basic Industries Corporation (SABIC)
recently announced their decision to suspend the development of a 600,000 metric ton per year
styrene project in Al Jubail, Saudi Arabia, which was scheduled to come on-stream in 2007, due to
rising construction expenses and the high cost of benzene feedstock. In addition, much of this new
capacity is being constructed in politically unstable regions of the world, such as the Middle
East, which may impact the timing of the start-up of this new capacity. If and when these new
units are completed, we would anticipate more difficult market conditions, especially in the export
markets, until the additional supply is absorbed by growth in styrene demand or significant
capacity rationalization occurs.
Given the market conditions in Asia and the high domestic raw materials and energy costs we
have been experiencing, most of our styrene sales over the last two years have been to customers in
the United States, Mexico, Canada and South America. We expect most of our styrene sales over the
next three to five years to also be in these geographic regions. Consequently, we are focusing our
efforts on increasing market share in these areas, while continuing to make occasional styrene
sales in Asia on an opportunistic basis. We may not, however, be successful in increasing our
market share in these geographic regions during this period and we cannot guarantee when, or if,
export market conditions to Asia will improve for North American styrene producers. We may also
explore mergers, acquisitions and joint ventures with other North American styrene producers that
could improve the domestic balance of supply and demand for styrene and provide us with improved
cash flows.
CMAI currently is not projecting any additional capacity increases in North America through
2010, with projected operating rates reaching a trough of 75% in 2007, and less than 80% operating
rates through 2010, without any major industry restructuring. Although we believe an improved
North American industry outlook is possible, this largely depends on a significant industry
restructuring. Styrene and polystyrene industry participants, including The DOW Chemical Company
and NOVA Chemicals Corporation have recently announced a desire to seek transactions which would
restructure the North American styrene and polystyrene industries, thereby improving the balance of
supply and demand in North America. Separately, new technology for the manufacture of propylene
oxide has been developed that should result in lower manufacturing costs for propylene oxide and
which does not produce styrene as a co-product, which could significantly reduce the future growth
of plants utilizing PO-SM technology.
Plasticizers. Plasticizers are produced from either ethylene-based linear alpha-olefins
feedstocks or propylene-based technology. Linear plasticizers typically receive a premium over
competing branched propylene-based products for customers that require enhanced performance
properties. However, the markets for competing plasticizers may be affected by the cost of the
underlying raw materials, especially when the cost of one olefin rises faster than the other, or by
the introduction of new products. Over the last few years, the price of linear alpha-olefins has
increased sharply as supply has declined, which has caused many consumers to switch to lower cost
branched propylene-based products and C4-based products, despite the loss of some performance
properties. Ultimately, we expect branched plasticizers to replace linear plasticizers for most
applications over the long-term. In addition, in 2005, BP Chemicals announced the permanent
closure of its linear alpha-olefins production facility in Pasadena, Texas, the primary source of
supply of this feedstock to the oxo-alcohols production unit at our plasticizers facility. As a
result, we modified our plasticizers facilities during the third quarter of 2006 to produce lower
cost branched plasticizers products and, on July 31, 2006, we permanently shut down our
oxo-alcohols production unit. Due to the closure of our oxo-alcohols unit and our conversion to
the production of branched plasticizers, the phthalate esters production unit at our plasticizers
facility now uses oxo-alcohols supplied by BASF.
Product Summary
The following table summarizes our principal products, including our capacity, the primary end
uses for each product, the raw materials used to produce each product and the major competitors for
each product. Capacity represents rated annual production capacity as of December 31, 2006,
which is calculated by estimating the number of days in a typical year that a production facility
is capable of operating after allowing for downtime for regular maintenance, and multiplying that
number of days by an amount equal to the facilitys optimal daily output based on the
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design feedstock mix. As the capacity of a facility is an estimated amount, actual production
may be more or less than capacity, and the following table does not reflect actual operating rates
of any of our production facilities for any given period of time.
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Sterling Product |
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Intermediate |
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(Capacity) |
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Products |
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Primary End Products |
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Raw Materials |
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Major Competitors |
Acetic Acid
(1.1 billion
pounds per year)
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Vinyl acetate monomer,
terephthalic acid,
and acetate solvents
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Adhesives, PET bottles,
fibers and surface coatings
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Methanol and Carbon
Monoxide
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Celanese AG, Eastman
Chemical Company and
Lyondell Chemical Company |
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Styrene
(1.7 billion
pounds per year)
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Polystyrene,
ABS/SAN resins,
styrene butadiene
latex and
unsaturated
polyester resins
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Building products, boat and
automotive components,
disposable cups and trays,
packaging and containers,
housewares, tires, audio and
video cassettes, luggage,
childrens toys, paper
coating, appliance parts and
carpet backing
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Benzene and Ethylene
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Lyondell Chemical
Company, Ineos, PLC,
Chevron Phillips Chemical
Company, Shell , Cos-Mar
(a joint venture of
General
Electric Company and
FINA Inc.), Nova
Corporation, SABIC,
Samsung Corporation and
Mitsubishi Corporation |
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Plasticizers
(200 million
pounds of esters and 130
million pounds of phthalic
anhydride per year)
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Flexible polyvinyl
chloride
(PVC)
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Flexible plastics, such as
shower curtains and liners,
floor coverings, cable
insulation, upholstery and
plastic molding
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Oxo-Alcohols
and Orthoxylene
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ExxonMobil Corporation,
Eastman Chemical
Company and BASF
Corporation |
Products
Acetic Acid. Our acetic acid is used primarily to manufacture vinyl acetate monomer, which is
used in a variety of products, including adhesives and surface coatings. We have the third largest
production capacity for acetic acid in North America. Our acetic acid unit has a rated annual
production capacity of approximately 1.1 billion pounds, which represents approximately 17% of
total North American capacity. All of our acetic acid production is sold to BP Chemicals, and we
are BP Chemicals sole source of production in the Americas. We sell our acetic acid to BP
Chemicals pursuant to a Production Agreement that extends until 2016. For a further description of
our agreement with BP Chemicals, please refer to Acetic Acid-BP Chemicals under Contracts.
Styrene. Styrene is a commodity chemical used to produce intermediate products such as
polystyrene, expandable polystyrene resins and ABS plastics, which are used in a wide variety of
products such as household goods, foam cups and containers, disposable food service items, toys,
packaging and other consumer and industrial products. We have the fourth largest production
capacity for styrene in North America. Our styrene unit is one of the largest in the world and has
a rated annual production capacity of approximately 1.7 billion pounds, which represents
approximately 11% of total North American capacity. Approximately 30% to 40% of our styrene
capacity is currently committed for sales in North America under long-standing customer
relationships. In addition, approximately 30% to 40% of our styrene capacity is currently being
used to produce styrene sold on the spot market, with the balance of our capacity available to
produce styrene for sales when market conditions warrant.
Plasticizers. Our plasticizers business is comprised of two separate products: phthalate
esters and phthalic anhydride, together commonly referred to as plasticizers. Our phthalate esters
are made from phthalic anhydride and oxo-alcohols, and phthalic anhydride is also sold as a
separate product. All of our plasticizers, which are used to make flexible plastics such as shower
curtains, floor coverings, automotive parts and construction materials, are sold to BASF pursuant
to a long-term production agreement that extends until 2013, subject to some limited early
termination rights held by BASF beginning in 2010. For a further description of our agreement with
BASF, please refer to Plasticizers-BASF under Contracts.
Sales and Marketing
We generally sell our petrochemicals products to customers for use in the manufacture of other
chemicals and products, which in turn are used in the production of a wide array of consumer goods
and industrial products throughout the world. We compete on the basis of product price, quality
and deliverability. We sell our petrochemicals products pursuant to:
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multi-year contracts; |
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conversion agreements; and |
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spot transactions in both the domestic and export markets. |
We have long-term agreements that provide for the dedication of 100% of our production of
acetic acid and plasticizers, each to one customer. Under our acetic acid agreement, we are
reimbursed for our actual fixed and variable manufacturing costs and also receive an agreed share
of the profits earned from this business. Under our plasticizers agreement, we are reimbursed for
our manufacturing costs and also receive a quarterly facility fee for each production unit
included in our plasticizers business, but do not share in the profits or losses from that
business. These agreements are intended to:
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optimize our capacity utilization rates;
· lower our selling, general and administrative expenses; |
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reduce our working capital requirements; |
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insulate our plasticizers operations from the effects of declining markets
and changes in raw materials prices; and |
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in some cases, gain access to certain improvements in manufacturing
process technology. |
Prices for styrene are determined by global market factors that are largely beyond our control
and we generally sell styrene at prevailing market prices. From time to time, we may resell raw
materials we purchased from others, purchase styrene for resale or sell ethylbenzene that we have
produced from our own purchased benzene and ethylene or from customer supplied raw materials. We
sell a significant portion of our committed volumes of styrene, and generate a significant portion
of our revenues from styrene sales under our conversion agreements. Under our conversion
agreements, the customer furnishes raw materials that we process into finished products. In
exchange, we receive a fee which covers our fixed and variable costs of production and may provide
an element of profit depending on the existing market conditions for styrene. These conversion
agreements help us maintain lower levels of working capital. Our conversion agreements are
designed to insulate us, to some extent, from the effects of declining styrene markets and changes
in raw materials prices, while allowing us to share in the benefits when styrene market conditions
are more favorable. The rest of our styrene is sold in the spot market by our direct sales force
or sales agents.
For information regarding our export sales, see Note 10 of the Notes to Consolidated
Financial Statements included in Item 8 of Part II of this Form 10-K.
Contracts
Our multi-year requirements contracts are described below.
Acetic Acid-BP Chemicals
In 1986, we entered into a long-term acetic acid Production Agreement with BP Chemicals, which
has since been amended several times. Under this Production Agreement, BP Chemicals has the
exclusive right to purchase all of our acetic acid production until July 31, 2016. BP Chemicals
markets all of the acetic acid that we produce and pays us, among other amounts, a portion of the
profits derived from their sales of the acetic acid we produce. In addition, BP Chemicals
reimburses us for 100% of our fixed and variable costs of acetic acid production. Pursuant to the
terms of this production agreement, beginning in August 2006, the portion of the profits we receive
from the sales of acetic acid produced at our plant increased and BP Chemicals is no longer
required to pay us the set monthly payment that we had received prior to that time. Based on
forecasted acetic acid market conditions for the next several years, we believe that this change
will result in improved profitability for us.
Plasticizers-BASF
Since 1986, we have provided all of our plasticizers production exclusively to BASF pursuant
to a production agreement, which has been amended several times. Under this production agreement,
BASF provides us with most of the required raw materials and markets the plasticizers we produce,
and is obligated to make certain fixed quarterly payments to us and to reimburse us monthly for our
actual production costs and capital expenditures relating to our plasticizers facility. Effective
January 1, 2006, we amended this production agreement to extend the term of the agreement until
2013, subject to some limited early termination rights held by BASF beginning in 2010, increase the
quarterly payments made to us by BASF and eliminate our participation in the profits and losses
realized by BASF in
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connection with the sale of the plasticizers we produce. Additionally, on April 28, 2006, BASF
notified us that it was exercising its right under the amended production agreement to terminate
its future obligations with respect to the operation of our oxo-alcohols production unit effective
July 31, 2006.
Sales to major customers constituting 10% or more of total revenues are included in Note 10 of
the Notes to Consolidated Financial Statements included in Item 8, Part II of this Form 10-K.
Raw Materials and Energy Resources
For most of our products, the aggregate cost of raw materials and energy resources is far
greater than the total of all other costs of production combined. As a result, an adequate supply
of raw materials and energy at reasonable prices and on acceptable terms is critical to the success
of our business. Most of the raw materials we use are global commodities that are made by a large
number of producers. Prices for many of these raw materials are subject to wide fluctuations for a
variety of reasons beyond our control. Although we believe that we will continue to be able to
secure adequate supplies of raw materials and energy, we may be unable to do so at acceptable
prices or payment terms. See Risk Factors. Under the Production Agreement with BP Chemicals and
our agreement with BASF, BP Chemicals is required to provide our methanol requirements to produce
acetic acid and BASF is required to provide us with most of the major raw materials necessary to
produce plasticizers. These sources of raw materials tend to mitigate certain risks typically
associated with obtaining raw materials, as well as decrease our working capital requirements.
Acetic Acid. Acetic acid is manufactured primarily from carbon monoxide and methanol.
Praxair supplies us with all of the carbon monoxide we require for the production of acetic acid
from a partial oxidation unit constructed by Praxair on land leased from us at our Texas City site.
Praxair is our single source for this raw material. Currently, our methanol requirements are
supplied by BP Chemicals under our long-term production agreement.
Styrene. We manufacture styrene by converting ethylene and benzene into ethylbenzene, which
we then process into styrene. Ethylene and benzene are both commodity petrochemicals and prices
for each can fluctuate widely due to significant changes in the availability of these products. We
currently purchase our benzene requirements on the spot market. We have a few multi-year
arrangements with major ethylene suppliers that provide a significant percentage of our estimated
requirements for purchased ethylene at generally prevailing and competitive market prices. Our
conversion agreements require that the other parties to these agreements furnish us with the
ethylene or benzene necessary to fulfill our conversion obligations. If customers for whom we
manufacture styrene under conversion agreements were to cease furnishing their own raw materials,
our requirements for purchased benzene and ethylene could significantly increase.
Plasticizers. The primary raw materials for plasticizers are oxo-alcohols and orthoxylene,
which are supplied by BASF under our long-term production agreement.
Technology and Licensing
In 1986, we acquired our Texas City site from Monsanto Company (Monsanto). In connection
with that acquisition, Monsanto granted us a non-exclusive, irrevocable and perpetual right and
license to use Monsantos technology and other technology Monsanto acquired through third-party
licenses in effect at the time of the acquisition. We use these licenses in the production of
styrene, acetic acid and plasticizers.
During 1991, BP Chemicals Ltd. (BPCL) purchased Monsantos acetic acid technology, subject
to existing licenses. Under a technology agreement with BP Chemicals and BPCL, BPCL granted us a
non-exclusive, irrevocable and perpetual right and license to use acetic acid technology owned by
BPCL and some of its affiliates at our Texas City site, including any new acetic acid technology
developed by BPCL at its acetic acid facilities in England or pursuant to the research and
development program provided by BPCL under the terms of such agreement.
Although we do not engage in alternative process research, we do monitor new technology
developments and, when we believe it is necessary, we typically seek to obtain licenses for process
improvements.
Competition
The petrochemical industry is highly competitive. Many of our competitors are larger and have
substantially greater financial resources than we have. Among our competitors are some of the
worlds largest chemical companies that, in contrast to us, have their own internal raw materials
supplies or their own internal uses for the products they produce. A significant portion of our
business is based upon widely available technology. The entrance of new
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competitors into the industry and the addition by existing competitors of new capacity could
have a negative impact on our ability to maintain existing market share or maintain or increase
profit margins, even during periods of increased demand for our products. You will find a list of
our principal competitors in the Product Summary table above.
Historically, profitability of the styrene industry has been affected by vigorous price
competition, which may intensify due to, among other things, new domestic and foreign industry
capacity. Several of our competitors have announced their intentions to build new styrene
production units outside the United States. In 2006, our competitors added 2.6 billion pounds of
new styrene capacity in Asia. Most of the remaining announced construction projects appear likely
to start up during 2007 and 2008, although it is not uncommon for announced construction to be
delayed. For example, Shell and Sabic recently announced their decision to suspend the development
of a 600,000 metric ton per year styrene project in Al Jubail, Saudi Arabia, which was scheduled to
come on-stream in 2007, due to rising construction expenses and the high cost of benzene feedstock.
In addition, much of this new capacity is being constructed in politically unstable regions of the
world, such as the Middle East, which may impact the timing of the start-up of this new capacity.
If and when these new units are completed, we would anticipate more difficult market conditions,
especially in the export markets, until the additional supply is absorbed by growth in styrene
demand or significant capacity rationalization occurs. Our styrene business is also impacted by
changes in the world economy, including changes in currency exchange rates. In general, weak
economic conditions, either in the United States or worldwide, tend to reduce demand and profit
margins for our styrene.
Foreign markets for our styrene may be affected by import laws and regulations. A significant
portion of our styrene is sold in North America, but we also make significant sales in Central
America, South America and Asia when market conditions are favorable. In 2006, our styrene export
sales accounted for approximately 10% of our total revenues.
Environmental, Health and Safety Matters
Our operations involve the handling, production, transportation, treatment and disposal of
materials that are classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements. Environmental
permits required for our operations are subject to periodic renewal and may be revoked or modified
for cause or when new or revised environmental requirements are implemented. Changing and
increasingly strict environmental requirements can affect the manufacture, handling, processing,
distribution and use of our chemical products and, if so affected, our business and operations may
be materially and adversely affected. In addition, changes in environmental requirements may cause
us to incur substantial costs in upgrading or redesigning our facilities and processes, including
our waste treatment, storage, disposal and other waste handling practices and equipment.
A business risk inherent in chemical operations is the potential for personal injury and
property damage claims from employees, contractors and their employees and nearby landowners and
occupants. While we believe our business operations and facilities generally are operated in
compliance with all applicable environmental and health and safety requirements in all material
respects, we cannot be sure that past practices or future operations will not result in material
claims or regulatory action, require material environmental expenditures or result in exposure or
injury claims by employees, contractors or their employees or the public. Some risk of
environmental costs and liabilities is inherent in our operations and products, as it is with other
companies engaged in similar businesses.
Our operating expenditures for environmental matters, mostly waste management and compliance,
were $20 million in both 2006 and 2005. We also spent $2 million for environmentally-related
capital projects in both 2006 and 2005. In 2007, we anticipate spending approximately $2 million
for capital projects related to waste management, incident prevention and environmental compliance.
We do not expect to make any capital expenditures in 2007 related to remediation of environmental
conditions.
In light of our historical expenditures and expected future results of operations and sources
of liquidity, we believe we will have adequate resources to conduct our operations in compliance
with applicable environmental, health and safety requirements. Nevertheless, we may be required to
make significant site and operational modifications that are not currently contemplated in order to
comply with changing facility permitting requirements and regulatory standards. Additionally, we
have incurred, and may continue to incur, liability for investigation and cleanup of waste or
contamination at our own facilities or at facilities operated by third parties where we have
disposed of waste. We continually review all estimates of potential environmental liabilities, but
we may not have identified or fully assessed all potential liabilities arising out of our past or
present operations or the amount necessary to investigate and remediate any conditions that may be
significant to us. It is our policy to make environmental, health and safety and replacement
capital expenditures a priority in order to ensure adequate environmental, health and safety
compliance at all times. In
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the event we should not have available to us, at any time, liquidity sources sufficient to fund any
of these expenditures, prudent business practice might require that we cease operations at the
affected facility to avoid exposing our employees and contract workers, the surrounding community
or the environment to potential harm.
Air emissions from our Texas City site are subject to certain permit requirements and
self-implementing emissions limitations and standards under state and federal laws. Our Texas City
site is located in an area that the Environmental Protection Agency (EPA) has classified as not
having attained the ambient air quality standards for ozone, which are controlled by direct
regulation of volatile organic compounds and nitrogen oxide (NOx) emissions. Our Texas City site
is also subject to the federal governments June 1997 National Ambient Air Quality Standards, which
lower the ozone and particulate matter concentration thresholds for attainment. The Texas
Commission for Environmental Quality (TCEQ) has imposed strict requirements on regulated
facilities, including our Texas City site, to ensure that the air quality control region will
achieve the ambient air quality standards for ozone. Local authorities also may impose new ozone
and particulate matter standards. Compliance with these stricter standards may substantially
increase our future NOx, volatile organic compounds and particulate matter emissions control costs.
On December 13, 2002, the TCEQ adopted a revised State Implementation Plan (SIP) to achieve
compliance with the 1-hour ozone standard of the Clean Air Act. The EPA approved this 1-hour
SIP, which calls for reduction of emissions of NOx at our Texas City site by approximately 80% by
the end of 2007. The current 1-hour SIP also requires monitoring of emissions of highly reactive
volatile organic carbons (HRVOCs), such as ethylene. The cost of compliance with the 1-hour
SIP at our Texas City site is estimated to be between $12 million and $14 million. This estimate
includes our share of capital expenditures to be made by S&L Cogeneration Company in order to
comply with the 1-hour SIP. To date, we have spent $10 million in capital on NOx reductions and
HRVOC monitoring, with $1 million of that amount spent in 2006. In April 2004, the
Houston-Galveston region was designated a moderate non-attainment area with respect to the 8-hour
ozone standard of the Clean Air Act, and compliance with this standard is required no later than
June 15, 2010. In December 2006, the TCEQ formally proposed revisions to the SIP in order to
achieve compliance with the 8-hour ozone standard. These proposed revisions (the 8-hour SIP)
will undergo review and revisions before final adoption by the TCEQ, which is expected in May 2007,
and will then be submitted to the EPA for approval one month after adoption. The current proposed
8-hour SIP calls for relatively modest additional controls which we believe would require very
little expense on our part. However, the proposed package may not receive EPA approval in its
current form, in which case additional controls or monitoring could be added before the rule
becomes finalized. It is difficult to predict the final cost of our compliance under the 8-hour
SIP, although we estimate that these additional costs will range from zero to $16 million in
capital expenditures and the purchase of allowances, depending on the terms of the final 8-hour
SIP.
To reduce the risk of offsite consequences from unanticipated events, we acquired a greenbelt
buffer zone adjacent to our Texas City site in 1991. We also participate in a regional air
monitoring network to monitor ambient air quality in the Texas City community.
Employees
As of December 31, 2006, we had 274 employees. All of our hourly employees at our Texas City
site, a total of 102 people, are covered by a collective bargaining agreement with the Texas City,
Texas Metal Trades Council, AFL-CIO, of Galveston County, Texas (the Union). Our current
collective bargaining agreement with the Union expires on May 1, 2007, and we expect to engage in
negotiations for a new collective bargaining agreement in April 2007. Although we believe our
relationship with our hourly employees is generally good, in connection with previous efforts to
reach new collective bargaining agreements we did lock out our employees for 16 weeks in 2002 and
our hourly employees engaged in a strike for one week in 2004. During the lockout and the strike,
our Texas City site was operated by our salaried workers and contract workers at comparable cost
without interruption, loss of production or environmental incident. Neither the lockout nor the
strike had a material adverse effect on our business, financial condition, results of operation or
cash flows.
Insurance
We maintain insurance coverage at levels that we believe are reasonable and typical for our
industry. A portion of our insurance coverage is provided by a captive insurance company
maintained by us and a few other chemical companies. However, we are not fully insured against all
potential hazards incident to our business. Additionally, we may incur losses beyond the limits
of, or outside the coverage of, our insurance. We maintain full replacement value insurance
coverage for property damage to our facilities and business interruption insurance. Nevertheless,
a significant interruption in the operation of one or more of our facilities could have a material
adverse effect on our business. As a result of market conditions, premiums and deductibles for
certain insurance policies can increase substantially and, in
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some instances, certain insurance may become unavailable or available only for reduced amounts of
coverage. The markets for many types of insurance coverage were negatively impacted by the 2005
hurricane season. Although we did not incur any direct damage from any hurricanes, our windstorm
related property damage and business interruption coverages were reduced when we renewed these
policies in 2006, and our non-windstorm related property damage and business interruption coverages
were renewed at historical levels but at higher premiums.
We do not currently carry terrorism coverage on our Texas City site. After the terrorist
attacks of September 11, 2001, many insurance carriers (including ours) created exclusions for
losses from terrorism from all risk property insurance policies. While separate terrorism
insurance coverage is available, the premiums for such coverage are very expensive, especially for
chemical facilities, and these policies are subject to very high deductibles. In addition,
available terrorism coverage typically excludes coverage for losses from acts of foreign
governments, as well as nuclear, biological and chemical attacks. Consequently, we believe that it
is not economically prudent to obtain terrorism insurance on the terms currently being offered in
the industry.
Access to Filings
Access to our annual reports on Form 10-K, quarterly reports on Form 10-Q, current reports on
Form 8-K and amendments to those reports filed with or furnished to the Securities and Exchange
Commission pursuant to Section 13(a) of the Exchange Act, as well as reports filed electronically
pursuant to Section 16(a) of the Exchange Act, may be obtained through our website
(http://www.sterlingchemicals.com). Our website provides a hyperlink to a third-party website
where these reports may be viewed and printed at no cost as soon as reasonably practicable after we
have electronically filed such material with the Securities and Exchange Commission. The contents
of our website (or the third party websites accessible through the hyperlinks) are not, and shall
not be deemed to be, incorporated into this report.
Item 1A. Risk Factors
In addition to the other information contained in this report, the following risk factors
should be considered carefully in evaluating our business. Our business, financial condition or
results of operations could be materially adversely affected by any of these risks. Please note
that additional risks not presently known by us, or that we currently deem immaterial, may also
impair our business and operations.
Risks Relating to Our Indebtedness
We have a significant amount of outstanding indebtedness which exposes us to a greater risk of
default. Additionally, restrictions contained in the agreements governing such indebtedness limit
our ability to react to changes in our business and to engage in certain corporate transactions.
As of December 31, 2006, we had approximately $101 million in outstanding indebtedness. Under
the terms of our existing 10% Senior Secured Notes due 2007 (our Secured Notes) and our revolving
credit facility dated December 19, 2002 with The CIT Group/Business Credit, Inc., as administrative
agent and a lender, and certain other lenders, our ability to incur additional indebtedness is
limited. Our existing indebtedness and the terms and conditions governing that indebtedness,
reduces our flexibility to effect corporate and operating actions, which in turn increases the risk
of default under these obligations. In particular, the terms and conditions governing our existing
indebtedness:
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require us to dedicate a substantial portion of our cash flow from operations to service
our existing debt service obligations, thereby reducing the availability of our cash flow
to fund working capital, capital expenditures and other general corporate expenditures; |
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increase our vulnerability to adverse general economic or industry conditions and limits
our flexibility in planning for, or reacting to, competition or changes in our business or
our industry; |
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limit our ability to obtain additional financing; |
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place restrictions on our ability to make strategic acquisitions, engage in mergers or
other fundamental changes, make capital expenditures, introduce new products or services or
exploit business opportunities; |
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make certain payments or investments, sale of assets, capital expenditures, engaging in
certain mergers and acquisitions and refinancing existing indebtedness more difficult; and |
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place us at a competitive disadvantage relative to competitors with lower levels of
indebtedness in relation to their overall size or less restrictive terms governing their
indebtedness. |
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Our ability to meet our expenses and debt obligations will depend on our future performance,
which will be affected by financial, business, economic, regulatory and other factors. We will not
be able to control many of these factors, such as economic conditions and governmental regulations.
We cannot be certain that our earnings will be sufficient to allow us to pay the principal and
interest on our debt, including the notes, and meet our other obligations. If we do not have enough
money, we may be required to refinance all or part of our existing debt, including the notes, sell
assets, borrow more money or raise equity. We may not be able to refinance our debt, sell assets,
borrow more money or raise equity on terms acceptable to us, if at all. Further, failing to comply
with the financial and other restrictive covenants in our indebtedness could result in an event of
default under such indebtedness, which could adversely affect our business, financial condition,
results of operations or cash flows.
The indebtedness represented by our Secured Notes, as well as the loans outstanding under our
revolving credit facility mature in 2007. We may not be able to refinance this indebtedness or
obtain a new revolving capital facility on terms and conditions as favorable to us as those of our
existing indebtedness or at all.
Our Secured Notes mature on December 19, 2007 and our revolving credit facility expires on
September 19, 2007. Based on our current projections, our cash flows will not allow us to repay or
Secured Notes on their maturity date, so we are currently in the process of refinancing our Secured
Notes. We may not be able to refinance our Secured Notes, or to obtain a renewed or new revolving
credit facility, on terms and conditions as favorable to us as the existing revolving credit
facility or at all. The inability to refinance our Secured Notes or to obtain a revolving credit
facility on commercially reasonable terms could require us to take actions such as selling assets,
seeking an additional equity investment or reducing or delaying capital expenditures, strategic
acquisitions, investments or alliances. Additionally, if we are unable to discharge our
obligations under our Secured Notes or our revolving credit facility on their respective maturity
dates, the holders of our Secured Notes or the lenders under our revolving credit facility will be
able to exercise certain remedies provided for in those instruments and under applicable law, such
as the institution of foreclosure actions, seeking judicial enforcement of our payment obligations
or the filing of an involuntary petition for bankruptcy.
Any failure to meet our debt obligations could harm our business, financial condition, results of
operations or cash flows.
If our cash flow and capital resources are insufficient to fund our debt obligations, we may
be forced to sell assets, seek additional equity or debt capital or restructure our debt. In
addition, any failure to make scheduled payments of interest and principal on our outstanding
indebtedness would likely result in a reduction of our credit rating, which could harm our ability
to incur additional indebtedness on acceptable terms. Our cash flow and capital resources may be
insufficient for payment of interest on and principal of our debt in the future, including payments
on the notes, and any such alternative measures may be unsuccessful or may not permit us to meet
scheduled debt service obligations, which could cause us to default on our obligations and impair
our liquidity.
Risks Related to Our Business
Cyclicality in the styrene markets has in the past and may in the future result in reduced
operating margins or operating losses.
Styrene, one of our principal products, is a commodity that exhibits wide swings in demand,
prices and margins based upon current and anticipated levels of supply and demand. Demand for our
styrene is largely influenced by the rate of growth of the worlds economy, with the growth rate of
the economy in Asia becoming increasingly more important. Our historical operating results reflect
the cyclical and volatile nature of the styrene markets and the petrochemicals industry generally.
These cycles are characterized by periods of tight supply, leading to increased operating rates and
higher margins, followed by periods of oversupply leading to reduced operating rates and lower
margins. In most cases, increases in supply are due to large increases in production capacity
resulting from the construction of new facilities or major expansions of existing facilities.
Typically, these types of expansions will cause available supply to greatly exceed demand for an
extended period. Weak economic conditions, either in the United States or in the international
markets generally, tend to result in a reduced growth in demand and profit margins for styrene,
which may in turn materially adversely affect our business, financial condition, results of
operations or cash flows.
Certain of our products are sold to only one customer.
In 2006, a single customer, BP Chemicals, accounted for 100% of our acetic acid revenues while
another customer, BASF, accounted for 100% of our plasticizers revenues. The termination of one or
more of the long-term contracts for
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the purchase of these products, or a material reduction in the amount of product purchased
under either of these contracts, could materially adversely affect our overall business, financial
condition, results of operations or cash flows.
A large portion of our styrene capacity is sold in the spot markets, rather than pursuant to
long-term contracts, which may result in lower profitability during periods of excess domestic or
global supply.
A large portion of our capacity for styrene is uncommitted and is therefore available for sale
in the spot markets. The current negative market conditions could affect us more severely than
competitors in our industry whose production is sold primarily pursuant to long-term contracts or
consumed internally. Future growth in demand for styrene may not be sufficient to alleviate any
existing or future conditions of excess industry capacity, and such conditions may be sustained or
may be further aggravated by anticipated or unanticipated capacity additions or other events.
During 2007, we expect to have approximately 30% to 40% of our styrene capacity committed to
long-term contracts. A loss of one or more of these contracts could result in increased styrene
sales to the domestic spot and export markets, which could materially adversely affect our
business, financial condition, results of operations or cash flows.
We may not be able to increase the price of our products to compensate for increases in natural gas
prices which may, in turn, decrease the competitiveness of our products in certain markets.
We use significant amounts of natural gas as fuel in the production of our products, which
makes the cost of producing our products particularly sensitive to changes in natural gas prices.
In addition, most of our suppliers use significant amounts of natural gas in the production of the
raw materials we buy, which results in increased prices for our raw materials when the price of
natural gas increases. There can be significant disparities in the prices for natural gas in
different parts of the world. Prices for styrene, on the other hand, tend to be consistent
throughout the world, after taking into account transportation costs. Consequently, when prices
for natural gas rise in the United States but not in other parts of the world, we may not be able
to recover these increased costs through higher sales prices, and our ability to compete with
producers elsewhere in the world may be diminished. In addition, many producers in other parts of
the world use oil-based processes rather than natural gas-based processes. Consequently, the
relationship between the price of crude oil and the price of natural gas can also affect our
competitiveness and our ability to recover increases in the price of natural gas through higher
product sales prices. Over the last few years, we have experienced periods when domestic prices
for natural gas resulted in our being unable to sell styrene in Europe or Asia at prices above our
variable costs of production, essentially closing those markets to sales of our styrene. In the
future, the domestic price for natural gas may adversely impact our competitiveness, which could
materially adversely affect on business, financial condition, results of operations or cash flows.
We may be unable to obtain raw materials at reasonable prices, on acceptable terms or at all.
For most of our products, the aggregate costs of raw materials and energy resources are far
greater than the total of all other costs of production combined. As a result, an adequate supply
of raw materials at reasonable prices and on acceptable terms is critical to the success of our
business. If we are unable to obtain raw materials at reasonable prices or on acceptable terms,
our results of operations are negatively affected. Most of the raw materials necessary for our
production of styrene are commodities and, consequently, are subject to wide fluctuations in prices
for a variety of reasons beyond our control. Several factors may impact the cost or supply of our
raw materials, including regional and global balances of supply and demand, the availability and
pricing for crude oil and the occurrence of plant outages and other supply disruptions. While the
markets for our products are generally global, prices and availability for most of our raw
materials are influenced by regional factors. As a result, we may pay higher prices for raw
materials than our competitors pay in other parts of the world or be unable to obtain raw materials
at times when they are available to our competitors, both of which may negatively impact our
competitiveness and our business, financial condition, results of operations or cash flows.
All of our primary raw materials are supplied by others pursuant to long-term contracts or
spot market purchases. While we often enter into supply agreements, as is the general practice in
our industry, these agreements typically provide for market-based pricing. Consequently, our
supply agreements provide only limited protection against price volatility. In addition, it has
become increasingly more difficult to secure long-term supply agreements for benzene, as benzene
producers appear to have shifted their approach towards the sale of benzene from dedicated supply
arrangements to predominantly spot sales in an active trading market. The markets for our raw
materials are also subject to disruptions. If our suppliers are unable to meet their obligations
under applicable supply agreements or we are otherwise unable to obtain reasonably priced raw
materials, our business may be disrupted. For example, ethylene became difficult to obtain after
Hurricane Katrina and Hurricane Rita shut down several production units over an extended period.
This limited the ability to purchase ethylene in the spot market at the same time when contract
suppliers were putting customers on allocation or declaring force majeure. In addition, we rely on
Praxair as our sole
15
supplier of carbon monoxide, which is a necessary raw material for our production of acetic
acid, and any disruption in the supply of carbon monoxide from Praxair will disrupt our production
of acetic acid since this gas is delivered directly by pipeline with no intermediate storage
capacity. In the case of either raw materials price increases or supply disruptions, we could
incur significant additional costs. While we attempt to match raw materials cost increases with
corresponding product price increases, we are not always able to raise product prices immediately
and, ultimately, our ability to pass on underlying cost increases to our customers is greatly
dependent upon product market conditions. Any underlying cost increase that we are not able to pass
on to our customers could materially adversely affect our business, financial condition, results of
operations or cash flows.
We may be unable to compete successfully with integrated and larger competitors.
We compete with some of the worlds largest chemical companies, most of whom are engaged in
much broader businesses and either internally supply significant portions of the raw materials they
need to produce styrene, or internally use significant amounts of the styrene they produce to make
derivative products. We do not make any of the primary raw materials required for styrene
production or convert any of our styrene into other products. Consequently, our production costs
may be higher than those of our competitors during periods when demand for required raw materials
exceeds supply and, in more extreme cases, we may not be able to obtain the required raw materials
in the market at times when our competitors are supplying their own raw materials internally. In
addition, as production costs are highly influenced by production rates, our absence of internal
uses for our styrene typically results in lower production rates, and consequently higher
production costs, at our facilities during periods when the balance of supply and demand for
styrene favors consumers. Our competitors who internally consume significant amounts of styrene,
have less volatile production rates and more stable production costs.
Our industry is highly competitive and our results are significantly impacted by manufacturing
costs.
We compete with some of the worlds largest chemical companies on the basis of product price,
quality and deliverability. However, prices for our styrene are determined by global market
factors that are largely beyond our control. Except with respect to our long-term contracts, we
generally sell our styrene at prevailing market prices. As a result, our financial performance
relative to our competitors, most of whom are larger than us, is greatly influenced by our
manufacturing costs.
The worsening of conditions in the styrene industry could cause us to generate losses significant
enough to warrant a shut down of our styrene plant.
While we intend to continue operating our styrene facilities for the foreseeable future, if
conditions in the styrene industry worsen, we may be required to close these facilities. In recent
years, relatively high costs of raw materials have resulted in higher styrene prices, negatively
impacting demand growth and compressing styrene margins. In addition, over the last two years,
these relatively higher raw materials prices have significantly limited our ability to sell styrene
into the Asian markets and high styrene prices have reduced styrene global demand growth rates.
Furthermore, several of our competitors have announced their intention to build new styrene
production units outside the United States, which may further increase the challenges we face in
selling styrene into the Asian markets. If any such new units are completed, we anticipate more
difficult market conditions, especially in the export markets. If our styrene margins decrease
significantly or our ability to sell into the export market decreases further, we may generate
significant losses which could cause us to close our styrene facilities without seeking strategic
alternatives and could materially adversely affect our business, financial condition, results of
operations or cash flows.
Our ability to realize increases in our acetic acid production capacity made possible through
capacity expansions is limited by the current inability to obtain sufficient quantities of carbon
monoxide.
Carbon monoxide is one of the principal raw materials required for acetic acid production.
Currently, all of the carbon monoxide we use in the production of acetic acid is supplied by
Praxair from a partial oxidation unit constructed by Praxair on land leased from us at our Texas
City site. Although our new acetic acid reactor installed in 2003 is capable of producing up to
1.7 billion pounds annually, Praxairs partial oxidation unit is not capable of supplying carbon
monoxide in quantities sufficient for more than approximately 1.2 billion pounds of annual acetic
acid production. Moreover, the supply of sufficient quantities of carbon monoxide will likely
require the construction of a new supply pipeline, which will require numerous third party and
regulatory consents, or a substantial expansion of the Praxair oxidation unit. The expansion of
the Praxair oxidation unit may not be cost effective and we may not be able to contract for the
supply of carbon monoxide in quantities sufficient to increase our annual acetic acid production to
1.7 billion pounds. Furthermore, the construction of a supply pipeline may require a substantial
period of time.
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The styrene industry has experienced several years of depressed conditions and some of our current
or potential styrene customers may be in troubled financial condition.
The styrene industry is highly volatile and has experienced several years of depressed
conditions. As a result, many of our styrene customers have suffered prolonged losses and
diminished liquidity. While we attempt to manage our credit exposure to our styrene customers on a
case-by-case basis through a variety of methods, including requiring letters of credit,
establishing credit limits or, in extreme cases, requiring cash-on-delivery for our products, we
cannot be sure that our styrene customers will not default on their obligations to us. A default
by one or more of our styrene customers on their payment obligations to us would have a negative
effect on our business, financial condition, results of operations or cash flows, which effect
could be material.
Our styrene technology is widely available and could become obsolete.
A significant portion of our styrene business is based upon widely available technology.
Accordingly, barriers to entry, apart from capital availability, are low in certain product
segments of our business, and the entrance of new competitors into the industry may reduce our
ability to capture improving profit margins in circumstances where capacity utilization in the
industry is increasing. Currently, a competing technology exists for the production of styrene
which allows for lower overall production economics than the technology we utilize. If this
technology becomes a more predominant method for producing styrene, it could materially adversely
affect our business, financial condition, results of operations or cash flows.
We sell a significant portion of styrene to international customers. Reliance on overseas markets
subjects us to significant risks inherent in operating internationally.
Our international operations are subject to a number of risks inherent to any business
operating in foreign countries. As we continue to sell our products to such countries, our
operations will encounter the following risks, among others:
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political and economic instability and disruptions; |
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the inability to collect amounts owed; |
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the inability to secure adequate shipping space for our products at acceptable prices,
which could adversely affect our competitiveness relative to producers located in close
proximity to our foreign customers; |
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terrorism, civil uprisings, riots and war, which can make it unsafe to continue operations; |
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the imposition of duties and tariffs, import and export controls; |
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decrees, laws, regulations, interpretations and court decisions under legal systems,
such as in the Peoples Republic of China, which are not always fully developed and which
may be retroactively applied and cause us to incur unanticipated or unrecoverable costs, as
well as delays which may result in real or opportunity costs; and |
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transportation delays and interruptions. |
We cannot predict the nature or the likelihood of any of these events. However, the occurrence of
any one or more of these events could have an adverse effect on our international sales by reducing
the demand for our products, decreasing the prices at which we can sell our products or otherwise
having an adverse effect on our business, financial condition, results of operations or cash
flows.
The markets for our products, and the prices we receive for our products, are based on
international supply and demand. In recent years, demand in Asia, particularly China, and
capacity expansions in Asia and the Middle East, have driven product price trends. China has
pursued an aggressive economic expansion in recent years. If this expansion ceased, or
significantly slowed, the markets for our products could be materially adversely affected.
Countries in Asia and in the Middle East have also completed or announced significant capacity
increases for most of the products we produce, and may expand production even further in the
future. These developments could have a significant negative impact on our ability to maintain
existing market share, sell products in the foreign or domestic markets or may adversely impact our
profit margins.
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We depend upon the continued operation of a single site for all of our production.
All of our products are produced at our Texas City site. Significant unscheduled downtime at
our Texas City site could have a material adverse effect on our business, financial condition,
results of operations or cash flows. Unanticipated downtime can occur for a variety of reasons,
including equipment breakdowns, interruptions in the supply of raw materials, power failures,
sabotage, natural forces or other hazards associated with the production of petrochemicals.
Although we maintain business interruption insurance, this insurance does not provide coverage for
business interruptions of less than 45 days and is limited in its overall coverage.
Our operations involve risks that may increase our operating costs, which could reduce our
profitability.
Although we take precautions to enhance the safety of our operations and minimize the risk of
disruptions, our operations are subject to hazards inherent in the manufacturing and marketing of
chemical products. These hazards include:
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pipeline or storage tank leaks and ruptures, explosions and fires; |
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severe weather and natural disasters; |
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mechanical failures, unscheduled downtimes, labor difficulties and transportation interruptions; |
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environmental remediation complications and |
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chemical spills and discharges or releases of toxic or hazardous substances or gases. |
Many of these hazards can cause bodily injury or loss of life, severe damage to or destruction of
property or equipment or environmental damage, and may result in suspension of operations or the
imposition of civil or criminal penalties and liabilities. Furthermore, we are subject to present
and future claims with respect to workplace exposure of our employees or contractors on our
premises or other persons located nearby, workers compensation and other matters.
Our operations are subject to operating hazards and unforeseen interruptions for which we may not
be adequately insured.
We maintain insurance coverage at levels that we believe are reasonable and typical for our
industry, portions of which are provided by a captive insurance company maintained by us and a few
other chemical companies. However, we are not fully insured against all potential hazards incident
to our business. Accordingly, our insurance coverage may be inadequate for any given risk or
liability, such as property damage suffered in hurricanes or from terrorist acts or business
interruption incurred from a loss of our supply of electricity or carbon monoxide. In addition,
our insurance companies may be incapable of honoring their commitments if an unusually high number
of claims are concurrently made against their policies. As a result of market conditions, premiums
and deductibles for certain insurance policies can increase substantially and, in some instances,
certain insurance may become unavailable or available only for reduced amounts of coverage. If we
were to incur a significant liability for which we were not fully insured, it could have a material
adverse effect on our business, financial condition, results of operations or cash flows. We can
make no assurances that we can renew our existing insurance coverages at commercially reasonable
rates or that such coverage will be adequate to cover future claims that may arise.
In addition, concerns about terrorist attacks, as well as other factors, have caused
significant increases in the cost of our insurance coverage. We have determined that it is not
economically prudent to obtain terrorism insurance and we do not carry terrorism insurance on our
property at this time. In the event of a terrorist attack impacting one or more of our production
units, we could lose the production and sales from one or more of these facilities, and the
facilities themselves, and could become liable for contamination or personal or property damage
from exposure to hazardous materials caused by a terrorist attack. Such loss of production, sales,
facilities or incurrence of liabilities could materially adversely affect our business, financial
condition, results of operations or cash flows.
Terrorist attacks, the current military action in Iraq, general instability in various OPEC member
nations and other attacks or acts of war in the United States and abroad may adversely affect the
markets in which we operate.
The attacks of September 11, 2001 and subsequent events, including the current military action
in Iraq, have caused instability in the United States and other financial markets and have led, and
may continue to lead, to further armed hostilities, prolonged military action in Iraq or further
acts of terrorism in the United States or abroad, which could
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cause further instability in the financial markets and in the markets for our products.
Current regional tensions and conflicts in various OPEC member nations, including the current
military action in Iraq, have caused, and may continue to cause, increased raw materials costs,
specifically raising the prices of oil and gas, which are used in our operations or affect the
prices of our raw materials. Furthermore, the terrorist attacks, subsequent events or future
developments in any of these areas may result in reduced demand from our customers for our
products. These developments could subject our operations to increased risks and, depending on
their magnitude, could have a material adverse effect on our business, financial condition, results
of operations or cash flows.
New regulations concerning the transportation of hazardous chemicals and the security of chemical
manufacturing facilities could result in higher operating costs.
Chemical manufacturing facilities may be at greater risk of future terrorist attacks than
other potential targets in the United States. As a result, the chemical industry has responded to
the issues surrounding the terrorist attacks of September 11, 2001 by starting new initiatives
relating to the security of chemicals industry facilities and the transportation of hazardous
chemicals in the United States. Simultaneously, local, state and federal governments have begun a
regulatory process that could lead to new regulations impacting the security of chemical plant
locations and the transportation of hazardous chemicals. Our business or our customers businesses
could be adversely affected because of the cost of complying with new security regulations.
We are subject to many environmental and safety regulations that may result in significant
unanticipated costs or liabilities or cause interruptions in our operations.
Our operations involve the handling, production, transportation, treatment and disposal of
materials that are classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements. We may incur
substantial costs, including fines, damages and criminal or civil sanctions, or experience
interruptions in our operations for actual or alleged violations or compliance requirements arising
under environmental laws, any of which could have a material adverse effect on our business,
financial condition, results of operations or cash flows. Our operations could result in
violations of environmental laws, including spills or other releases of hazardous substances to the
environment. In the event of a catastrophic incident, we could incur material costs. Furthermore,
we may be liable for the costs of investigating and cleaning up environmental contamination on or
from our properties or at off-site locations where we disposed of or arranged for the disposal or
treatment of hazardous materials. Based on available information, we believe that the costs to
investigate and remediate known contamination will not have a material adverse effect on our
business, financial condition, results of operations or cash flows. However, if significant
previously unknown contamination is discovered, or if existing laws or their enforcement change,
then the resulting expenditures could have a material adverse effect on our business, financial
condition, results of operations or cash flows.
Environmental, health and safety laws, regulations and permit requirements, and the potential
for further expanded laws, regulations and permit requirements may increase our costs or reduce
demand for our products and thereby negatively affect our business. Environmental permits required
for our operations are subject to periodic renewal and may be revoked or modified for cause or when
new or revised environmental requirements are implemented. Changing and increasingly strict
environmental requirements and the potential for further expanded regulation may increase our costs
and can affect the manufacturing, handling, processing, distribution and use of our products. If
so affected, our business and operations may be materially and adversely affected. In addition,
changes in these requirements may cause us to incur substantial costs in upgrading or redesigning
our facilities and processes, including our waste treatment, storage, disposal and other waste
handling practices and equipment. For these reasons, we may need to make capital expenditures
beyond those currently anticipated to comply with existing or future environmental or safety laws.
Approximately 37% of our employees are covered by a collective bargaining agreement that expires on
May 1, 2007. Disputes with the union representing these employees or our inability to conclude a
favorable renewal of the collective bargaining agreement may negatively affect our business.
As of December 31, 2006, we had 274 employees, of whom approximately 37% (all of our hourly
employees at our Texas City site) are covered by a collective bargaining agreement which expires on
May 1, 2007, and we expect to engage in negotiations for a new collective bargaining agreement in
April 2007. In connection with two previous renegotiations of this collective bargaining
agreement, we locked out our employees for 16 weeks and our hourly employees engaged in a one-week
strike. Any further labor disturbances could have a material adverse effect on our business,
financial condition, results of operations or cash flows. During the lockout and the strike, our
Texas City site was operated by our salaried workers and contract workers at comparable cost
without interruption, loss of production or environmental incident. Neither the lockout nor the
strike had a material adverse effect on our business, financial
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condition, results of operations or cash flows, although we can give no assurances that future
similar occurrences will not have such an impact.
A failure to retain our key employees could adversely affect our business.
We are dependent on the services of the members of our senior management team to remain
competitive in our industry. There is a risk that we will not be able to retain or replace these
key employees. Our current key employees are subject to employment conditions or arrangements that
permit the employees to terminate their employment without notice. The loss of any member of our
senior management team could materially adversely affect our business, financial condition, results
of operations or cash flows.
Transactions consummated pursuant to our plan of reorganization could result in the imposition of
material tax liabilities.
Prior to our emergence from bankruptcy, we eliminated our holding company structure by merging
Sterling Chemicals Holdings, Inc. with and into us. We believe that this merger qualifies as a
tax-free reorganization pursuant to Section 368(a)(1)(G) of the Internal Revenue Code (commonly
referred to as a G Reorganization) for United States federal income tax purposes. However, a
judicial determination that this merger did not qualify as a G Reorganization would result in
additional federal income tax liability which could materially adversely affect our business,
financial condition, results of operations and cash flows.
We may not successfully implement our acquisition strategy, and acquisitions that we pursue may
present unforeseen integration obstacles or costs, increase our leverage or negatively impact our
performance.
We may not be able to identify suitable acquisition candidates, and the expense incurred in
consummating acquisitions of related businesses, or our failure to integrate such businesses
successfully into our existing businesses, could affect our growth or result in our incurring
unanticipated expenses and losses. Furthermore, we may not be able to realize any anticipated
benefits from acquisitions. From time to time we evaluate potential acquisitions and may complete
one or more significant acquisitions in the future. To finance an acquisition we may need to incur
debt or issue equity. However, we may not be able to obtain favorable debt or equity financing to
complete an acquisition, or at all. In particular, the lack of an active trading market in our
common stock, as well as the dilutive terms of our outstanding Series A convertible preferred
stock, may make our common stock unattractive as consideration for an acquisition. The process of
integrating acquired operations into our existing operations may result in unforeseen operating
difficulties and may require significant financial resources that would otherwise be available for
the ongoing development or expansion of existing operations. Some of the risks associated with our
acquisition strategy, which could materially adversely affect our business, financial condition,
results of operations or cash flows, include:
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potential disruption of our ongoing business and distraction of management; |
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unexpected loss of key employees or customers of an acquired business; |
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conforming an acquired business standards, processes, procedures or controls with our operations; |
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coordinating new product and process development; |
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hiring additional management or other critical personnel; |
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encountering unknown contingent liabilities which could be material; and |
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increasing the scope, geographic diversity and complexity of our operations. |
Our acquisition strategy may not be favorably received by customers, and we may not realize
any anticipated benefits from acquisitions.
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Risks Relating to the Ownership of our Common Stock
Our common stock is thinly traded. There is no active trading market for our common stock and an
active trading market may not develop.
Our common stock is not listed on any national or regional securities exchange. Quotations
for shares of our common stock are listed by certain members of the National Association of
Securities Dealers, Inc. on the OTC Electronic Bulletin Board. In recent years, the trading volume
of our common stock has been very low and the transactions that have occurred were typically
effected in transactions for which reliable market quotations have not been available. An active
trading market may not develop or, if developed, may not continue for our equity securities, and a
holder of any of these securities may find it difficult to dispose of, or to obtain accurate
quotations as to the market value of such securities.
We have a significant stockholder which has the ability to control our actions.
Resurgence Asset Management, L.L.C. and its and its affiliates managed funds and accounts
(collectively, Resurgence) own in excess of 98% of our preferred stock and over 60% of our common
stock, representing ownership of over 82% of the total voting power of our equity. The interests
of Resurgence may differ from our other stockholders and Resurgence may vote their interests in a
manner that may adversely affect our other stockholders. Through their direct and indirect
interests in us, Resurgence is in a position to influence the outcome of most matters requiring a
stockholder vote. This concentrated ownership makes it less likely that any other holder or group
of holders of common stock would be able to influence the way we are managed or the direction of
our business. These factors also may delay or prevent a change in our management or voting
control.
Our preferred stock pays a quarterly stock dividend that is dilutive to the holders of our common
stock.
Our shares of preferred stock carry a cumulative dividend rate of 4% per quarter, payable in
additional shares of preferred stock. Our shares of preferred stock are convertible at the option
of the holder into shares of our common stock and vote as if so converted on all matters presented
to the holders of our common stock for a vote. Consequently, each dividend paid in additional
shares of our preferred stock has a dilutive effect on our shares of common stock and increases the
percentage of the total voting power of equity owned by Resurgence. In 2006, we issued an
additional 594.832 shares of our preferred stock (which is convertible into 594,832 shares of our
common stock) in dividends, which represents 8.6% of the current total voting power of our equity
securities.
The existence of our preferred stock and limited liquidity of our common stock may limit our
ability to utilize our equity to pursue strategic initiatives that may otherwise exist.
The existence of our preferred stock and the limited trading market of our common stock (as
discussed above) could make it more difficult to use these instruments as part of implementing our
strategy to grow the business.
Item 2. Properties
Our petrochemicals site is located in Texas City, Texas, approximately 45 miles south of
Houston, on a 290-acre site on Galveston Bay near many other chemical manufacturing complexes and
refineries. We own all of the real property which comprises our Texas City site and we own the
acetic acid, styrene and plasticizers manufacturing facilities located at the site. We also lease
a portion of our Texas City site to Praxair, who constructed a partial oxidation unit on that land,
and lease a portion of our Texas City site to S&L Cogeneration Company, a 50/50 joint venture
between us and Praxair Energy Resources, Inc., who constructed a cogeneration facility on that
land. Our Texas City site offers approximately 135 acres for future expansion by us or by other
companies who could benefit from our existing infrastructure and facilities, and includes a
greenbelt around the northern edge of the plant site. We own 126 railcars and, at our Texas City
site, we have facilities to load and unload our products and raw materials in ocean-going vessels,
barges, trucks and railcars.
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Substantially all of our Texas City, Texas site, and the tangible properties located thereon,
are subject to a lien securing our obligations under our Secured Notes.
We lease the space for our principal executive offices, located at 333 Clay Street, Suite 3600
in Houston, Texas.
We believe our properties and equipment are sufficient to conduct our business.
Item 3. Legal Proceedings
On July 5, 2005, Patrick B. McCarthy, an employee of Kinder-Morgan, was seriously injured at
Kinder-Morgan, Inc.s facilities near Cincinnati, Ohio while attempting to offload a railcar
containing one of our plasticizers products. On October 28, 2005, Mr. McCarthy and his family
filed a suit in the Court of Common Pleas, Hamilton County, Ohio (Case No. A0509144) against us,
BASF and five other defendants. The plaintiffs are seeking a minimum amount of $150,000 in damages
related to medical expenses and loss of earnings and earnings capacity, among other things, and
punitive damages. Discovery is ongoing in this case as to the underlying cause of the accident and
the parties respective liability, if any. At this time, it is impossible to determine what, if
any, liability we will have for this incident and we will vigorously defend the suit. We believe
that all, or substantially all, of any liability imposed upon us as a result of this suit and our
related out-of-pocket costs and expenses will be covered by our insurance policies, subject to a $1
million deductible. We do not believe that this incident will have a material adverse affect on
our business, financial position, results of operations or cash flows, although we cannot guarantee
that a material adverse effect will not occur.
On August 17, 2006, we initiated an arbitration proceeding against BP Chemicals to resolve a
dispute involving the interpretation of provisions of our acetic acid production agreement with BP
Chemicals. Under the production agreement, BP Chemicals reimburses our manufacturing expenses and
pays us a percentage of the profits derived from the sales of the acetic acid we produce.
Historically, the costs of manufacturing charged to our acetic acid business, and reimbursed by BP
Chemicals, included the amounts we paid Praxair for carbon monoxide, hydrogen and a blend of carbon
monoxide and hydrogen commonly referred to as blend gas. Our acetic acid business has always
used all of the carbon monoxide produced by Praxair, other than the small amount of carbon monoxide
included in the blend gas. Until recently, all of the blend gas produced by Praxair was used by
the oxo-alcohols plant included in our plasticizers business. During the period when the
oxo-alcohols plant was operating, BP Chemicals was compensated for the use of this blend gas by our
oxo-alcohols plant through a credit to the amount of our manufacturing expenses reimbursed by BP
Chemicals. Effective July 1, 2006, we permanently closed our oxo-alcohols plant. BP Chemicals has
taken the position that it is entitled to continue to deduct a portion of the blend gas credit from
the reimbursement of our manufacturing expenses, even though our oxo-alcohols plant has been closed
and is no longer taking any blend gas and the Praxair facilities have been modified so that the
carbon monoxide previously used in blend gas is now being delivered to our acetic acid operations.
Effective August 1, 2006, BP Chemicals began short paying our invoices for manufacturing expenses
by the portion of the credit that BP Chemicals claims should continue through July 31, 2016.
The disputed portion of the credit averaged approximately $0.3 million per month during 2006. We
are also seeking additional damages from BP Chemicals in the arbitration based on what we believe
are breaches of duty by BP Chemicals. The arbitration hearing was scheduled for August 6, 2007.
However, pursuant to an agreement reached in principle on January 31, 2007, the parties will abate
the arbitration proceeding for a period of at least six months while they attempt to reach a
negotiated settlement. As part of the agreement, BP Chemicals reimbursed us $0.8 million on
February 5, 2007, which was 50% of the accrued disputed credit, and will continue to pay 50% of the
disputed amount each month during the period of negotiation. The parties have stipulated that the
payments are made without prejudice, in that BP Chemicals is not admitting liability and continues
to insist that we remain liable for the disputed portion of the blend gas credit. According to the
agreement, if a settlement is not reached within six months, either party may reinstate the
arbitration process, and seek a hearing date consistent with the current schedule, or approximately
seven months thereafter. Under the January 31, 2007 agreement, if the arbitration proceeds to an
award, the amounts paid by BP Chemicals will be credited against any sums awarded to us or refunded
by us to BP Chemicals, depending on the ruling of the arbitration panel. We believe that our
acetic acid production agreement does not contemplate the continuation of any portion of the blend
gas credit under these circumstances and will vigorously pursue our position.
Although we are in a dispute with BP Chemicals over the interpretation of this contractual
provision, we believe that we continue to have a constructive working relationship with BP
Chemicals, as has been the case since 1986. As part of the settlement negotiations over the blend
gas calculation, we may discuss an extension of the term of the acetic acid production agreement.
On February 21, 2007, we received a summons naming us as a defendant in a class action suit,
Case No. H-07-0625 filed in the United States District Court, Southern District of Texas, Houston
Division. The plaintiffs comprising the
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proposed class are employees and retired employees of Sterling Fibers, Inc., one of our former
subsidiaries that was sold in connection with our Plan of Reorganization in 2002. The plaintiffs
are alleging that we were not permitted to increase their premiums for retiree medical insurance
based on a provision contained in the asset purchase agreement between us and Cytec Industries Inc.
governing our purchase of our former acrylic fibers business in 1997. During our bankruptcy, we
specifically rejected this asset purchase agreement. The plaintiffs are making claims for breach
of contract and claims under the Employee Retirement Income Security Act and seek damages,
declaratory relief, punitive damages and attorneys fees. At this time, we have not determined
what, if any, liability we may have in this matter and intend to vigorously defend this action. We
do not believe a loss related to this matter is probable, therefore no liability associated with
this matter has been accrued. Currently, we are unable to determine the possible range of loss
related to this matter, if any.
We are subject to various other claims and legal actions that arise in the ordinary course of
our business. We do not believe that any of these claims and actions, separately or in the
aggregate, will have a material adverse effect on our business, financial position, results of
operation or cash flows, although we cannot guarantee that a material adverse effect will not
occur.
Item 4. Submission of Matters to a Vote of Security Holders
No matters were submitted to a vote of security holders during the fourth quarter of 2006.
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PART II
Item 5. Market for Registrants Common Equity and Related Stockholder Matters
Our common stock, par value $0.01 per share, is currently quoted on the Over-the-Counter
(OTC) Electronic Bulletin Board maintained by the National Association of Securities Dealers,
Inc. under the symbol SCHI. The following table contains information about the high and low
sales prices per share of our common stock for the last two years. Information about OTC Electronic
Bulletin Board bid quotations represents prices between dealers, does not include retail mark-ups,
mark-downs or commissions, and may not necessarily represent actual transactions. Quotations on
the OTC Electronic Bulletin Board are sporadic, and currently there is no established public
trading market for our common stock.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
First |
|
Second |
|
Third |
|
Fourth |
|
|
Quarter |
|
Quarter |
|
Quarter |
|
Quarter |
2006 High |
|
$ |
11.50 |
|
|
$ |
15.00 |
|
|
$ |
14.90 |
|
|
$ |
15.00 |
|
Low |
|
$ |
10.00 |
|
|
$ |
10.25 |
|
|
$ |
13.10 |
|
|
$ |
12.48 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 High |
|
$ |
46.50 |
|
|
$ |
41.00 |
|
|
$ |
37.00 |
|
|
$ |
25.50 |
|
Low |
|
$ |
35.05 |
|
|
$ |
26.00 |
|
|
$ |
22.00 |
|
|
$ |
11.77 |
|
The last reported sale price per share of our common stock as reported on the OTC Electronic
Bulletin Board on March 9, 2007 was $11.00. As of March 9, 2007, there were 328 holders of record
of our common stock. This number does not include stockholders for whom shares are held in a
nominee or street name.
Dividend Policy
We have not declared or paid any cash dividends with respect to our common stock since we
emerged from bankruptcy in December 2002. We do not presently intend to pay cash dividends with
respect to our common stock for the foreseeable future. In addition, we cannot pay dividends on
our shares of common stock under the indenture for our Secured Notes or under our revolving credit
facility. The payment of cash dividends, if any, will be made only from assets legally available
for that purpose, and will depend on our financial condition, results of operations, current and
anticipated capital requirements, general business conditions, restrictions under our existing debt
instruments and other factors deemed relevant by our Board of Directors.
Equity Compensation Plan
Under our 2002 Stock Plan, officers, key employees and consultants, as designated by our Board
of Directors or Compensation Committee, may be issued stock options, stock awards, stock
appreciation rights or stock units. Our 2002 Stock Plan is administered by our Board of Directors,
in consultation with our Compensation Committee, and may be amended or modified from time to time
by our Board of Directors in accordance with its terms. Our Board of Directors or Compensation
Committee determines the exercise price of stock options, any applicable vesting provisions and
other terms and provisions of each grant in accordance with our 2002 Stock Plan. Options granted
under our 2002 Stock Plan become fully exercisable in the event of the optionees termination of
employment by reason of death, disability or retirement, and may become fully exercisable in the
event of a change of control. No option may be exercised after the tenth anniversary of the date
of grant or the earlier termination of the option. We have reserved 363,914 shares of our common
stock for issuance under the 2002 Stock Plan (subject to adjustment). On February 11, 2003, we
granted certain of our officers and key employees, options to purchase 326,000 shares of our common
stock under our 2002 Stock Plan at an exercise price of $31.60 per share, 15,833 of which have been
exercised and 59,167 of which have lapsed or expired without being exercised. On November 5, 2004,
we granted one of our officers options to purchase 27,500 shares of our common stock under our 2002
Stock Plan at an exercise price of $31.60 per share. We have not made any other awards under our
2002 Stock Plan.
24
The following table provides information regarding securities authorized for issuance under
our 2002 Stock Plan as of December 31, 2006:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Number of securities |
|
|
|
|
|
|
|
|
remaining available for |
|
|
Number of securities to |
|
Weighted-average |
|
future issuance under |
|
|
be issued upon exercise |
|
exercise price of |
|
equity compensation plans |
|
|
of outstanding options, |
|
outstanding options, |
|
(excluding securities |
Plan Category |
|
warrants and rights |
|
warrants and rights |
|
reflected in first column |
Equity
compensation plans
approved by
security
holders(1) |
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
85,414 |
|
Equity compensation
plans not approved
by security holders |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
85,414 |
|
|
|
|
(1) |
|
Our 2002 Stock Plan was authorized and established under our Plan of Reorganization,
which became effective on December 19, 2002. Our Plan of Reorganization provided that,
without any further act or authorization, confirmation of our Plan of Reorganization and entry
of the confirmation order was deemed to satisfy all applicable federal and state law
requirements and all listing standards of any securities exchange for approval by the board of
directors or the stockholders of our 2002 Stock Plan. No additional stockholder approval of
our 2002 Stock Plan has been obtained. |
Performance Graph
The following performance graph compares our cumulative total stockholder return on shares of
our common stock for a four-year period with the cumulative total return of the Standard & Poors
500 Stock Index (the S & P 500 Index) and the Standard & Poors Diversified Chemicals Index (the
S & P Chemicals Index). The graph assumes the investment of $100 on December 31, 2002 in shares
of our common stock, the S & P 500 Index and the S & P Chemicals Index and the reinvestment of
dividends.
COMPARISON
OF 4 YEAR CUMULATIVE TOTAL RETURN*
Among Sterling Chemicals Inc., The S & P 500 Index
And The S & P Diversified Chemicals Index
|
|
|
* |
|
$100 invested on 1/3/03 in stock or on 12/31/02 in
index-including reinvestment of dividends.
Fiscal year ending December 31. |
|
|
|
Copyright © 2007, Standard & Poors, a division of The McGraw-Hill Companies, Inc. All rights reserved. www.researchdatagroup.com/S&P.htm |
25
Item 6. Selected Financial Data
The following table sets forth selected financial data with respect to our consolidated
financial condition and consolidated results of operations and should be read in conjunction with
our historical consolidated financial statements and related notes, Item 7. Managements
Discussion and Analysis of Financial Condition and Results of Operations and our Financial
Statements and Supplementary Data included in Item 8 of this Form 10-K.
On July 16, 2001,
Sterling Chemicals Holdings, Inc. and its subsidiaries, including us, filed voluntary petitions for
reorganization under Chapter 11 of the United States Bankruptcy Code. Our Plan of Reorganization
was confirmed on November 20, 2002 and, on December 19, 2002, we emerged from bankruptcy. Due to
the implementation of fresh-start accounting upon our emergence from bankruptcy, we refer to
ourselves as Predecessor Sterling for periods on or before December 19, 2002 and Reorganized
Sterling for periods after December 19, 2002. Prior to December 6, 2002, all issued and
outstanding shares of Predecessor Sterlings capital stock were held by Sterling Chemicals
Holdings, Inc. and, accordingly, per share data prior to December 19, 2002 is not presented.
The consolidated statements of operations information for the years ended December 31, 2006,
2005, 2004 and 2003 and the transition period from December 20, 2002 to December 31, 2002, and the
consolidated balance sheet information as of December 31, 2006, 2005, 2004, 2003 and 2002, reflect
the financial position and operating results after giving effect to our plan of reorganization and
the application of the principles of fresh-start accounting in accordance with the provisions of
Statement of Position 90-7, Financial Reporting by Entities in Reorganization under the Bankruptcy
Code. Accordingly, such financial information is not comparable to the historical financial
information before December 20, 2002. During 2002, we changed our fiscal year end from September
30 to December 31.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reorganized Sterling |
|
|
Predecessor Sterling |
|
|
Year ended |
|
Year ended |
|
Year ended |
|
Year ended |
|
December 20 to |
|
|
October 1 to |
|
Fiscal Year Ended |
|
|
December 31, |
|
December 31, |
|
December 31, |
|
December 31, |
|
December 31, |
|
|
December 19, |
|
September 30, |
|
|
2006 |
|
2005 |
|
2004 |
|
2003 |
|
2002 |
|
|
2002 |
|
2002 |
|
|
|
|
|
|
|
|
|
|
(In Thousands, Except Per Share Data) |
|
|
|
|
|
|
|
|
|
Operating Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Revenues |
|
$ |
667,544 |
|
|
$ |
641,886 |
|
|
$ |
655,353 |
|
|
$ |
518,772 |
|
|
$ |
12,211 |
|
|
|
$ |
98,575 |
|
|
$ |
375,095 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit (loss) |
|
|
12,826 |
|
|
|
(11,248 |
) |
|
|
22,344 |
|
|
|
23,790 |
|
|
|
1,494 |
|
|
|
|
6,471 |
|
|
|
47,530 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing
operations(1) |
|
|
(104,622 |
) |
|
|
(18,508 |
) |
|
|
(39,881 |
) |
|
|
1,270 |
|
|
|
(553 |
) |
|
|
|
230,145 |
|
|
|
(32,685 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued
operations(2) |
|
|
(997 |
) |
|
|
(11,060 |
) |
|
|
(22,763 |
) |
|
|
(15,469 |
) |
|
|
(991 |
) |
|
|
|
188,466 |
|
|
|
(3,301 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Per Share Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss attributable to common
stockholders |
|
$ |
(40.26 |
) |
|
$ |
(12.94 |
) |
|
$ |
(24.30 |
) |
|
$ |
(6.84 |
) |
|
$ |
(0.61 |
) |
|
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss from continuing
operations attributable to
common stockholders |
|
|
(39.91 |
) |
|
|
(9.03 |
) |
|
|
(16.24 |
) |
|
|
(1.36 |
) |
|
|
(0.26 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Cash dividends |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
26
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reorganized Sterling |
|
|
Predecessor Sterling |
|
|
Year ended |
|
Year ended |
|
Year ended |
|
Year ended |
|
December 20 to |
|
|
October 1 to |
|
Fiscal Year Ended |
|
|
December 31, |
|
December 31, |
|
December 31, |
|
December 31, |
|
December 31, |
|
|
December 19, |
|
September 30, |
|
|
2006 |
|
2005 |
|
2004 |
|
2003 |
|
2002 |
|
|
2002 |
|
2002 |
|
|
|
|
|
|
|
|
|
|
(Dollars in Thousands) |
|
|
|
|
|
|
|
|
|
Balance Sheet Data: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Working capital(3)(6) |
|
$ |
90,124 |
|
|
$ |
76,605 |
|
|
$ |
106,767 |
|
|
$ |
137,412 |
|
|
$ |
149,518 |
|
|
|
$ |
163,638 |
|
|
$ |
154,988 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total assets |
|
|
245,823 |
|
|
|
386,594 |
|
|
|
473,553 |
|
|
|
550,503 |
|
|
|
547,170 |
|
|
|
|
546,014 |
|
|
|
489,648 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-term debt (excluding
current portion of long-term
debt)(4)(6) |
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
100,579 |
|
|
|
94,275 |
|
|
|
|
94,275 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Stockholders equity
(deficiency in assets)
(5) |
|
|
(22,766 |
) |
|
|
80,285 |
|
|
|
120,083 |
|
|
|
189,436 |
|
|
|
209,011 |
|
|
|
|
210,725 |
|
|
|
(611,477 |
) |
|
|
|
(1) |
|
During 2006, we recorded a $127.7 million impairment charge to our styrene assets.
There was a deferred tax benefit of $45 million in connection with this impairment, which was
offset by deferred tax expense of $28 million in connection with the recording of a valuation
allowance against our deferred tax assets. During 2004, we recorded a $48.5 million goodwill
impairment charge. Also during 2004, we recorded a pension curtailment gain of $13 million.
The period from October 1, 2002 through December 19, 2002 includes a net loss on fresh-start
adjustments of $203 million, along with a net gain on debt restructuring of $458 million.
During fiscal year ended September 30, 2002, we recorded $56.8 million of deferred
tax expense to reflect a full valuation allowance on our U.S. deferred tax assets. |
|
(2) |
|
During 2005, we announced that we were exiting the acrylonitrile business and
related derivatives operations. During 2004, we recorded a $22 million pre-tax impairment
charge related to our acrylonitrile long-lived assets. On December 19, 2002, pursuant to our
plan of reorganization, we sold our pulp chemicals business to Superior Propane,
Inc. for approximately $373 million and our acrylic fibers business to local
management of that business for nominal consideration. The operating results of these
businesses have been reported as discontinued operations in the consolidated statement of
operations and cash flows, and the assets and liabilities of these businesses have been
presented separately as assets and liabilities related to discontinued operations in our
consolidated balance sheet. |
|
(3) |
|
Working capital as of December 31, 2006, 2005, 2004, 2003, 2002 and September 30,
2002 includes net assets (liabilities) of discontinued operations of $(0.2) million, $(2)
million, $55 million, $57 million, $27 million and $164 million, respectively. Working
capital as of September 30, 2002 excludes pre-petition liabilities. |
|
(4) |
|
The balance as of September 30, 2002 excludes long-term debt of $418.4 million and
$295.0 million, classified as pre-petition liabilities subject to compromise and
pre-petition liabilities not subject to compromise, respectively. |
|
(5) |
|
The balance as of December 31, 2006 includes an increase in Stockholders equity of
$6.7 million (net of tax) due to the adoption of Statement of Financial Accounting Standards
No. 158, Employers Accounting for Defined Benefit Pension and Other Postretirement Plans
(SFAS No. 158). |
|
(6) |
|
As of December 31, 2006, we reclassified $101 million of debt due in December
2007 to long-term based on our ability and intent to refinance the debt on a long-term basis. |
27
Item 7. Managements Discussion and Analysis of Financial Condition and Results of Operations
Overview
Business
We are a leading North American producer of selected petrochemicals used to manufacture a wide
array of consumer goods and industrial products throughout the world. Our primary products are
acetic acid, styrene and plasticizers.
Our acetic acid is used primarily to manufacture vinyl acetate monomer, which is used in a
variety of products, including adhesives and surface coatings. All of our acetic acid production
is sold to BP Amoco Chemical Company (BP Chemicals), and we are BP Chemicals sole source of
acetic acid production in the Americas. We sell our acetic acid to BP Chemicals pursuant to the
Production Agreement that extends until 2016. The Production Agreement provides us with a portion
of the profits derived from BP Chemicals sales of the acetic acid we produce and reimbursement of
100% of our fixed and variable costs of production. This Production Agreement has provided us with
a steadily increasing source of income since the inception of this relationship in 1986 and, over
the last three years, we have operated at over 100% of capacity and at utilization rates greater
than the industry average. We believe we have one of the lowest cost acetic acid facilities in the
world. Our acetic acid facility utilizes BP Chemicals proprietary carbonylation technology, or
Cativa Technology, which we believe offers several advantages over competing production methods,
including lower energy requirements and lower fixed and variable costs. We also jointly invest with
BP Chemicals in capital expenditures related to our acetic acid facility. Acetic acid production
has two major raw materials requirements methanol and carbon monoxide. BP Chemicals, a producer
of methanol, supplies 100% of our methanol requirements related to our production of acetic acid.
All of the carbon monoxide we use in the production of acetic acid is supplied by Praxair Hydrogen
Supply, Inc. (Praxair) from a partial oxidation unit constructed by Praxair on land leased from
us at our Texas City site.
Styrene is a commodity chemical used to produce intermediate products such as polystyrene,
expandable polystyrene resins and ABS plastics, which are used in a wide variety of products such
as household goods, foam cups and containers, disposable food service items, toys, packaging and
other consumer and industrial products. Approximately 30% to 40% of our styrene capacity is
currently committed for sales in North America under long-standing customer relationships. In
addition, approximately 30% to 40% of our styrene capacity is sold on the spot market, with the
balance of our capacity available to produce styrene for sales throughout the world when market
conditions warrant. We had one customer contract, which represented a significant portion of our
2006 North American committed sales volumes, expire at the end of 2006 and that contract was not
renewed. We are currently pursuing renewal of another contract that expires in 2007, as well as
additional contract volumes with new customers. We may not be successful in renewing these
expiring contracts or obtaining new contract customers. If we are unsuccessful, we may lower our
styrene production levels or sell more of our styrene production in the spot markets, both domestic
and export, which could materially adversely affect our business, financial condition, results of
operations or cash flows.
All of our plasticizers, which are used to make flexible plastics, such as shower curtains,
floor coverings, automotive parts and construction materials, are produced exclusively for BASF
Corporation (BASF) pursuant to a long-term production agreement that extends until 2013,
subject to some limited early termination rights held by BASF beginning in 2010. Under our
agreement with BASF, BASF provides us with most of the required raw materials, markets the
plasticizers we produce, and is obligated to make certain fixed quarterly payments to us and to
reimburse us monthly for our actual production costs and capital expenditures relating to our
plasticizers facility.
We manufacture all of our petrochemicals products at our site in Texas City, Texas. In terms
of production capacity, our Texas City site has the sixth largest acetic acid facility in the world
and the 3rd largest styrene facility in North America. Our Texas City site, which covers an area
of 290 acres, is strategically located on Galveston Bay and benefits from a deep-water dock capable
of handling ships with up to a 40-foot draft, as well as four barge docks, direct access to Union
Pacific and Burlington Northern railways with in-motion rail scales on site, truck loading racks
and weigh scales, stainless and mild steel storage tanks, three waste deepwells, 135 acres of
available land zoned for heavy industrial use, additional land zoned for light industrial use and a
supportive political environment for growth. In addition, we are in the heart of one of the
largest petrochemical complexes on the Gulf Coast and as a result have on-site access to a number
of key raw material pipelines as well as close proximity to a number of the larger refinery
complexes that provide some of our principal raw materials.
As shown below, our rated annual production capacity as of December 31, 2006 is among the
highest in North America for styrene and acetic acid.
|
|
|
|
|
|
|
|
|
|
|
|
|
Percent of |
|
|
|
|
|
|
|
|
Total North |
|
|
|
|
|
|
Rated Annual |
|
American |
|
North American |
|
Global |
Product |
|
Production Capacity |
|
Capacity |
|
Market Position |
|
Production Capacity |
Acetic Acid |
|
1.1 billion pounds |
|
17% |
|
3 |
|
24 billion pounds |
|
Styrene |
|
1.7 billion pounds |
|
11% |
|
4 |
|
63 billion pounds |
28
We generally sell our petrochemicals products to customers for use in the manufacture of
other chemicals and products, which in turn are used in the production of a wide array of consumer
goods and industrial products throughout the world. The North American acetic acid industry tends
to sell most of its products through long-term sales agreements having cost plus pricing
mechanisms, eliminating much of the volatility seen in other petrochemicals products and resulting
in more stable and predictable earnings and profit margins. Styrene is a commodity and exhibits
wide swings in prices and profit margins based upon current and anticipated levels of supply and
demand. Although exceptions occasionally occur, as a general rule, if styrene profit margins are
favorable, our overall financial performance is good, but our overall financial performance suffers
when styrene margins are unfavorable. The market for styrene roughly follows repetitive cycles,
and general trends in the supply and demand balance may be observed over time. However, it is
difficult, if not impossible, to definitively predict when market conditions will be favorable or
unfavorable.
Acetic Acid. The North American acetic acid industry is enjoying a period of sustained
domestic demand growth. as well as substantial export demand. This has led to current North
American industry utilization rates of 86% and Tecnon OrbiChem projects utilization rates to
increase to over 98% by 2013. The North American acetic acid industry is inherently less cyclical
than many other petrochemical products due to a number of important features.
There are only four large producers of acetic acid in North America and historically these
producers have made capacity additions in a disciplined and incremental manner, primarily using
small expansion projects or exploiting debottlenecking opportunities. In addition, the leading
technology required to manufacture acetic acid is controlled by two global companies, which permits
these companies to control the pace of new capacity additions through the licensing or development
of such additional capacity. The limited availability of this technology also creates a
significant barrier to entry into our industry by potential competitors. Additionally, currently
there is no planned development of new acetic acid capacity contemplated in the Middle East,
primarily due to the higher costs of feedstocks in that region.
Global production capacity of acetic acid as of December 31, 2006 was approximately 24 billion
pounds per year, with current North American production capacity at approximately 7 billion pounds
per year. The North American acetic acid market is mature and well developed and is dominated by
four major producers that account for over 94% of the production capacity of acetic acid in North
America. Demand for acetic acid is linked to the demand for vinyl acetate monomer, a key
intermediate in the production of a wide array of polymers. Vinyl acetate monomer is the largest
derivative of acetic acid, representing over 40% of total demand. Annual global production of
vinyl acetate monomer is expected to increase from 10.4 billion pounds in 2005 to 12.2 billion
pounds in 2010.
The North American acetic acid industry tends to sell most of its products through long-term
sales agreements having cost plus pricing mechanisms, eliminating much of the volatility seen in
other petrochemicals products and resulting in more stable and predictable earnings and profit
margins.
Several acetic acid capacity additions have occurred since 1998, including an expansion of our
acetic acid unit from 800 million pounds of rated annual production capacity to 1.1 billion pounds
during 2005. These capacity additions were somewhat offset by reductions of approximately 1.6
billion pounds in annual global capacity from the shutdown of various outdated acetic acid plants
from 1999 through 2001. In 2006, BP Chemicals closed two of its outdated acetic acid production
units in Hull, England that had a combined annual capacity of approximately 500 million pounds
(which had been sold primarily in Europe and South America). We and BP Chemicals are reviewing
further expansion of our acetic acid plant in 2008 or 2009.
Styrene. The North American styrene industry is currently in a protracted down cycle,
primarily as a result of over-supply. This shift is the result of two major developments. Export
demand has historically represented over 20% of North American production capacity. Regional cost
pressures in addition to new production capacity being added in Asia and the Middle East, have made
it difficult for North American producers to compete in these export markets on a continuous basis.
In addition, a significant amount of styrene capacity has been added globally over the past five
to ten years by producers of propylene oxide using so-called PO-SM technology, which produces
styrene as a co-product. Propylene oxide is a key intermediate in the production of polyurethane,
and polyurethane demand growth has been significantly greater than demand growth for styrene,
exacerbating the over-supply of styrene. During periods of over-supply, production rates for
styrene producers decrease significantly. Production rates in North America are currently
estimated by Chemical Market Associates, Inc. (CMAI) to be 75% of capacity. When production
rates are low, unit production costs increase due to the allocation of fixed costs over a lower
production volume and a reduction in the efficiency of the manufacturing unit, both in energy usage
and in the conversion rates for raw materials. Compounding these cost impacts, prices for the
principal styrene raw materials, benzene and ethylene, are currently near historical highs, putting
pressure on margins on styrene sales even though styrene contract prices are at near historic
highs.
29
According to CMAI, benzene and ethylene prices are expected to decline by approximately 8% and
7%, respectively, on average over each of the next five years.
The financial performance of styrene is primarily a function of sales prices, the costs of raw
materials and energy and sales volumes. In contrast, under the Production Agreement with BP
Chemicals and our agreement with BASF, BP Chemicals is required to provide the methanol to produce
acetic acid and BASF is required to provide us with most of the major raw materials necessary to
plasticizers. These sources of raw materials tend to mitigate certain risks typically associated
with fluctuating raw materials costs, as well as decrease our working capital requirements. While
changes in the prices for styrene may be tracked through a variety of sources, a change in price
does not necessarily result in a corresponding change in our financial performance. When the price
of styrene increases or decreases, our overall financial performance may improve, decline or stay
roughly the same depending upon the extent and direction of changes in our costs for raw materials
and energy and our production rates. The aggregate cost of raw materials and energy resources is
far greater than all other costs of producing styrene combined. We use significant amounts of
natural gas as fuel in the production of styrene, and the producers of most of our raw materials
use significant amounts of natural gas in their production. As a result, our production and raw
materials costs increase or decrease based upon changes in the price for natural gas. Natural gas
and most of our raw materials are commodities and, consequently, are subject to wide fluctuations
in prices, which can, and often do, move independently of changes in the prices for our products.
Prices for, and the availability of, natural gas and many of our raw materials are largely based on
regional factors, which can result in wide disparities in prices in different parts of the world or
shortages or unavailability in some regions at the same time when these raw materials are plentiful
in other parts of the world. Prices for styrene, on the other hand, tend to be more consistent
throughout the world, after taking into account transportation costs. Consequently, changes in
prices for natural gas and raw materials tend to impact the margin on our styrene sales rather than
the price of styrene, with margins increasing when natural gas and raw materials costs decline and
vice versa. In addition, many producers in other parts of the world use oil-based processes rather
than natural gas-based processes. Subsequently, the relationship between the price of crude oil
and the price of natural gas can either increase or decrease our competitiveness depending on their
relative values at any particular point in time. Sales volumes influence our overall financial
performance in a variety of ways. As a general rule, increases in sales volumes will result in an
increase in overall revenues and vice versa, although this is not necessarily the case since the
price for styrene can change dramatically from month-to-month. More importantly, changes in
production rates impact the average cost per pound of styrene produced. If more pounds are
produced, our fixed costs are spread over a greater number of pounds resulting in a lower average
cost to produce each pound. In addition, our styrene production rates influence the overall
efficiency of our styrene manufacturing unit and the yields we receive from our raw materials.
Over the last five years, China has been the driver for growth in styrene demand, representing
approximately 75% of the worlds styrene demand growth in that period. Historically, we have
positioned ourselves to take advantage of peaks in the Asian styrene markets, with a large portion
of our styrene capacity not being committed under long-term arrangements. However, over the last
two years, relatively high benzene and domestic natural gas prices have significantly limited our
ability to sell styrene into the Asian markets, and high styrene prices have reduced styrene global
demand growth rates. In addition, several of our competitors have announced their intention to
build new styrene production units outside the United States, further complicating our ability to
sell styrene into the Asian markets. In 2006, our competitors added 2.6 billion pounds of new
styrene capacity in Asia. The majority of the remaining announced construction projects are
scheduled to start up between 2007 and 2009, although it is not uncommon for announced construction
to be delayed. For example, Shell Oil Company and Saudi Basic Industries Corporation recently
announced their decision to suspend the development of a 600,000 metric ton per year styrene
project in Al Jubail, Saudi Arabia, which was scheduled to come on-stream in 2007, due to rising
construction expenses and the high cost of benzene feedstock. In addition, much of this new
capacity is being constructed in politically unstable regions of the world, such as the Middle
East, which may impact the timing of the start-up of this new capacity. If and when these new
units are completed, we would anticipate more difficult market conditions, especially in the export
markets, until the additional supply is absorbed by growth in styrene demand or significant
capacity rationalization occurs.
Given the market conditions in Asia and the high domestic raw materials and energy costs we
have been experiencing, most of our styrene sales over the last two years have been to customers in
the United States, Mexico, Canada and South America. We expect most of our styrene sales over the
next three to five years to also be in these geographic regions. Consequently, we are focusing our
efforts on increasing market share in these areas, while continuing to make occasional styrene
sales in Asia on an opportunistic basis. We may not, however, be successful in increasing our
market share in these geographic regions during this period and we cannot guarantee when, or if,
export market conditions to Asia will improve for North American styrene producers. We may also
explore mergers, acquisitions, and joint ventures with other North American styrene producers that
could improve the domestic balance of supply and demand for styrene and provide us with improved
cash flows.
30
CMAI currently is not projecting any additional capacity increases in North America through
2010, with projected operating rates reaching a trough of 75% in 2007, and less than 80% operating
rates through 2010, without any major industry restructuring. Although we believe an improved
North American industry outlook is possible, this largely
depends on a significant industry restructuring. Styrene and polystyrene industry
participants, including The DOW Chemical Company and NOVA Chemicals Corporation have recently
announced a desire to seek transactions which would restructure the North American styrene and
polystyrene industries, thereby improving the balance of supply and demand in North America.
Separately, new technology for the manufacture of propylene oxide has been developed that should
result in lower manufacturing costs for propylene oxide and which does not produce styrene as a
co-product, which could significantly reduce the future growth of plants utilizing PO-SM
technology.
Our styrene facilities consist of two reaction trains, a north train and a south train. On
September 22, 2005, during a shut down of our plant in anticipation of Hurricane Rita, the
superheater in the south train of our styrene facility was significantly damaged by a fire, forcing
a closure of the south train until repairs could be completed. In addition, the north train
reactor of our styrene facility sustained internal damage as a result of this incident and,
although still capable of producing product, the reactor damage caused significant raw material
yield and energy inefficiencies. On January 12, 2006, we shut down the north train of our styrene
facilities to make repairs to the reactor and replace the existing catalyst. In February 2006,
both the north and south trains were re-started. During these shutdowns, we fully met our supply
obligations to our contract styrene customers through the operation of the north train of our
styrene facilities, supplemented by open market purchases of styrene. The total cost for these
repairs was approximately $11 million. We also filed a claim for approximately $12 million under
our business interruption insurance policies. During the second quarter of 2006, we received an
advance payment from our insurance companies of $3 million. In August 2006, we settled the claim
with our insurance carriers for a total of $15 million, including the $3 million advance payment.
During the fourth quarter of 2006, we performed an asset impairment analysis on our styrene
production unit. This analysis was performed due to recent industry forecasts, forecasted negative
cash flow generated by our styrene business over the next few years and the uncertainty surrounding
the ability of the North American styrene industry to successfully restructure. Our management
determined that a triggering event, as defined in Statement of Financial Accounting Standards No.
144, Accounting for the Impairment or Disposal of Long Lived Assets (SFAS No. 144), had
occurred and an asset impairment analysis was performed. We analyzed the undiscounted cash flow
stream from our styrene business over the next seven years, which represents the remaining book
life of our styrene assets, and compared it to the $128 million net book carrying value of our
styrene unit and related assets. This analysis showed that the undiscounted projected cash flow
stream from our styrene business was less than the net book carrying value of our styrene unit and
related assets. As a result, we performed a discounted cash flow analysis and subsequently
concluded that our styrene unit and related assets were impaired. While we are still operating our
styrene unit, our analysis led us to conclude that our styrene assets should be written down to
zero. This write-down caused us to record a $128 million impairment in December 2006.
Plasticizers. Historically, we have produced ethylene-based linear plasticizers, which
typically receive a premium over competing branched propylene-based products for customers that
require enhanced performance properties. However, the markets for competing plasticizers can be
affected by the cost of the underlying raw materials, especially when the cost of one olefin rises
faster than the other, or by the introduction of new products. One of the raw materials for linear
plasticizers is a product known as linear alpha-olefins. Over the last few years, the price of
linear alpha-olefins has increased sharply as supply has declined, which has caused many consumers
to switch to lower cost branched propylene-based products and C4-based products, despite the loss
of some performance properties. Ultimately, we expect branched plasticizers to replace linear
plasticizers for most applications over the long-term. As a result, we modified our plasticizers
facilities during the third quarter of 2006 to produce lower cost branched plasticizers products.
In 2005, BP Chemicals announced the permanent closure of its linear alpha-olefins production
facility in Pasadena, Texas, the primary source of supply of this feedstock to the oxo-alcohols
production unit at our plasticizers facility. After pursuing various alternative uses for our
oxo-alcohols unit, we were unable to secure an alternative use for this facility. As a result, we
permanently shut down our oxo-alcohols production unit on July 31, 2006. Due to the closure of our
oxo-alcohols unit and our conversion to the production of branched plasticizers, the phthalate
esters production unit at our plasticizers facility now uses oxo-alcohols supplied by BASF that
have a different chemical composition.
Discontinued Operations
On September 16, 2005, we announced that we were exiting the acrylonitrile business and
related derivative operations. Our decision was based on a history of operating losses incurred by
our acrylonitrile and derivatives
31
businesses, and was made after a full review and analysis of our strategic alternatives. Our
acrylonitrile and derivatives businesses had sustained losses in recent years and had been shut
down since February of 2005.
In accordance with SFAS No. 144, we have reported the operating results of these businesses as
discontinued operations in our consolidated statement of operations and cash flows, and we have
presented the assets and liabilities of these businesses separately in our consolidated balance
sheet.
Results of Operations
The following table sets forth revenues, gross profit (loss) and net loss from continuing
operations for 2006, 2005 and 2004:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands) |
Revenues |
|
$ |
667,544 |
|
|
$ |
641,886 |
|
|
$ |
655,353 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit (loss) |
|
|
12,826 |
|
|
|
(11,248 |
) |
|
|
22,344 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing
operations
|
|
|
(104,662 |
) |
|
|
(18,508 |
) |
|
|
(39,881 |
) |
Comparison of 2006 to 2005
Revenues and Loss from continuing operations
Our revenues were $668 million in 2006, an increase of 4% over the $642 million in revenues we
recorded in 2005. This increase in revenues resulted primarily from an increase in acetic acid and
styrene sales prices. We recorded a net loss from continuing operations of $105 million in 2006,
compared to the net loss of $19 million we recorded in 2005. This increase in net loss was
primarily due to the $128 million impairment charge to our styrene assets that we recorded in 2006.
Revenues from acetic acid and plasticizers were $143 million in 2006, a 12% increase over the
$128 million in revenues we recorded in 2005. This increase in revenues was due to a 14% increase
in acetic acid revenues and a 6% increase in plasticizers revenues, primarily due to increases in
sales prices. We achieved both monthly and annual production records in our acetic acid business
during 2006.
Revenues from our styrene operations were $525 million in 2006, an increase of 2% over the
$514 million in revenues we recorded in 2005. Direct sales prices for styrene increased 10% from
those realized during 2005. Spot prices for styrene, a component of our direct sales prices,
ranged from $0.45 to $0.60 per pound during 2006, compared to $0.44 to $0.62 per pound during 2005.
Our total sales volumes for styrene in 2006 were 7% lower than in 2005. During 2006, prices for
benzene, one of the primary raw materials required for styrene production, increased 10% over the
prices we paid for benzene in 2005, and prices for ethylene, the other primary raw material
required for styrene production, increased 2% over the prices we paid for ethylene in 2005.
Average costs for natural gas, another major component in the cost of manufacturing styrene,
decreased 13% during 2006 compared to average natural gas costs during 2005. Margins on our
styrene sales in 2006 increased from those realized in 2005, primarily due to slightly improved
market conditions. As noted previously, we recorded an impairment of $128 million in 2006 related
to our styrene production unit.
Selling, general & administrative expenses
Our selling, general and administrative expenses were $10 million in 2006 compared to $8
million in 2005. This increase in 2006 was primarily due to the approximately $1 million in
expenditures we incurred in professional fees to explore potential new business opportunities, and
the $1 million we expensed for bad debts in 2006 compared to the $2 million credit for bad debts we
recorded in 2005. This increase in the allowance for doubtful accounts balance as of December 31,
2006 resulted primarily from the cumulative sum of disputed invoices related to our disagreement
with BP Chemicals described in Item 3, Part I of this Form 10-K.
32
Other expense (income)
We recorded other income of $16 million in 2006, which primarily consisted of the recognition
of final settlement of our claims under our property damage and business interruption insurance
policies related to the September 2005 fire that occurred in our styrene unit.
Provision (benefit) for income taxes
During 2006, our effective tax rate was 12% compared to 37% in 2005. This change in the
effective rate was the result of a $28 million increase in the valuation allowance related to
certain deferred tax assets during 2006. The styrene impairment discussed above resulted in the
reversal of $45 million in deferred tax liabilities. As of December 31, 2006, we had an available
U.S. federal income tax net operating loss carryforward (NOL) of approximately $85 million
(representing a deferred tax asset of $30 million), which expires during the years 2023 through
2026. Deferred tax assets are regularly assessed for recoverability based on both historical and
anticipated earnings levels, and a valuation allowance is recorded when it is more likely than not
that these amounts will not be recovered. As a result of our analysis, we have concluded that an
additional valuation allowance is needed against our deferred tax assets in the amount of $28
million, which brings our total valuation allowance to $30 million and results in an overall net
deferred tax asset balance of $4 million. We have also recorded a $4 million liability relating to
certain tax contingencies that we have identified.
Loss from discontinued operations, net of tax
We recorded a net loss from discontinued operations of $1 million in 2006 compared to a loss
of $11 million in 2005. The $1 million loss in 2006 represents closure costs related to our
acrylonitrile business, partially offset by asset sales related to that business. We expect to
incur approximately $1 million of costs during the first half of 2007 to complete the dismantling
of this facility. The loss of $11 million in 2005 included costs of $9 million related to our exit
from the acrylonitrile and related derivatives businesses.
Comparison of 2005 to 2004
Revenues and Loss from continuing operations
Our revenues were $642 million in 2005, a decrease of 2% from the $655 million in revenues we
recorded in 2004. This decrease in revenues resulted primarily from a reduction in styrene
revenues due to a change in customer mix and lost volumes of styrene following the fire that
occurred in our styrene unit in September 2005. As a result of this curtailed ability to produce
styrene, we sold a larger percentage of our overall styrene sales under conversion arrangements
during 2005. We recorded a net loss from continuing operations of $19 million for 2005, compared
to a net loss of $40 million recorded in 2004. This difference between these two years was
significantly influenced by the $48 million impairment to goodwill we recorded in 2004 and a
reduction in gross profit in 2005 due to the impact of Hurricane Rita and the fire in our styrene
unit.
Revenues from acetic acid and plasticizers were $128 million in 2005, a slight increase from
the $126 million in revenues we recorded in 2004. This slight increase in revenues resulted from a
7% increase in acetic acid revenues offset by a 6% decrease in plasticizers revenues. We achieved
record monthly production rates in our acetic acid business during 2005.
Revenues from our styrene operations were $514 million in 2005, a decrease of 3% from the $530
million in revenues we recorded in 2004. Direct sales prices for styrene increased 6% from those
realized during 2004. Spot prices for styrene, a component of our direct sales prices, ranged from
$0.44 to $0.62 per pound during 2005, compared to $0.37 to $0.63 per pound during 2004. Our total
sales volumes for styrene in 2005 were 1% lower than in 2004. During 2005, prices for benzene, one
of the primary raw materials required for styrene production, increased 2% over the prices we paid
for benzene in 2004, and prices for ethylene, the other primary raw material required for styrene
production, were 35% higher than the prices we paid for ethylene in 2004. Average costs for
natural gas, another major component in the cost of manufacturing styrene, increased 23% during
2005 compared to average natural gas costs during 2004. Margins on our styrene sales in 2005
decreased from those realized in 2004, primarily as a result of higher raw materials costs and the
impact of Hurricane Rita and the fire in our styrene unit.
33
Selling, general & administrative expenses
Our selling, general and administrative expenses were $8 million in 2005 compared to $11
million in 2004. This reduction was primarily due to a $2 million reduction in our allowance for
doubtful accounts resulting from a decrease in total accounts receivable, as well as a decrease in
balances with customers having greater credit risk.
Organizational efficiency project
During the last half of 2004, we developed an organizational efficiency project involving the
design, development and implementation of uniform and standardized systems, processes and policies
to improve our production, maintenance and process efficiencies, and our logistics materials
management and procurement functions. During 2005, we reduced our fixed costs by more than $20
million per year, representing a 15% reduction in our annual fixed costs. Approximately 10% to 15%
of these cost savings accrue to the benefit of some of our customers under the cost reimbursement
provisions of our production agreements.
Provision (benefit) for income taxes
During 2005, our effective tax rate was 37% compared to 16% in 2004. This difference in the
effective rate was a result of the $48.5 million impairment of goodwill recorded during 2004, which
was a non-tax deductible charge.
Loss from discontinued operations, net of tax
We recorded a net loss from discontinued operations of $11 million in 2005 compared to a loss
of $23 million in 2004. The loss of $11 million in 2005 included costs of $9 million related to
our exit from the acrylonitrile and related derivatives businesses. These costs included accruals
for contractual obligations due in 2006 and asset impairments. The loss of $23 million in 2004
included a pre-tax impairment charge of our long-lived acrylonitrile assets of $22 million.
Liquidity and Capital Resources
On December 19, 2002, we issued $94.3 million in original principal amount of our Secured
Notes. Our Secured Notes are senior secured obligations and rank equally in right of payment with
all of our other existing and future senior indebtedness, and senior in right of payment to all of
our existing and future subordinated indebtedness. Our Secured Notes are guaranteed by Sterling
Chemicals Energy, Inc. (Sterling Energy), our only wholly owned subsidiary. Sterling Energys
guaranty ranks equally in right of payment with all of its existing and future senior indebtedness,
and senior in right of payment to all of its existing and future subordinated indebtedness. Our
Secured Notes and Sterling Energys guaranty are secured by a first priority lien on all of our
production facilities and related assets.
Our Secured Notes bear interest at an annual rate of 10%, payable semi-annually on June 15 and
December 15 of each year. Until December 19, 2004, we were permitted under certain circumstances
to pay interest on our Secured Notes through the issuance of additional Secured Notes rather than
the payment of cash at an interest rate of 13 3/8% per annum. In December 2003,
we made an interest payment on our Secured Notes at the higher rate through the issuance of $6.3
million in original principal amount of additional Secured Notes, increasing the aggregate
principal amount of outstanding Secured Notes to $100.6 million. We have made all other interest
payments on our Secured Notes in cash. We may redeem our Secured Notes at any time at a redemption
price of 100% of the outstanding principal amount thereof plus accrued and unpaid interest, subject
to compliance with the terms of our revolving credit facility. In addition, in the event of a
specified change of control or the sale of our facility in Texas City, Texas, we are required to
offer to repurchase our Secured Notes at 101% of the outstanding principal amount thereof plus
accrued and unpaid interest. Under certain circumstances, we are also required to use the proceeds
of other asset sales to repurchase those Secured Notes tendered by the holders at a price equal to
100% of the outstanding principal amount thereof plus accrued and unpaid interest.
The indenture governing our Secured Notes contains numerous covenants and conditions,
including, but not limited to, restrictions on our ability to incur indebtedness, create liens,
sell assets, make investments, make capital expenditures, engage in mergers and acquisitions and
pay dividends. The indenture also includes various circumstances and conditions that would, upon
their occurrence and subject in certain cases to notice and grace periods, create an event of
default thereunder. However, the indenture does not require us to satisfy any financial ratios or
maintenance tests.
On March 1, 2007, we commenced an offer to repurchase all of our outstanding Secured Notes
(our tender offer).
34
Concurrently with our tender offer, we solicited consents from the holders
of our Secured Notes to, among other things, eliminate certain covenants contained in the indenture
governing our Secured Notes. The consent solicitation expired at
5:00 p.m., New York Time, on March 14, 2007, at which time we received consents
from the requisite principal amount of Secured Notes to amend our indenture. The supplemental indenture we entered into to effect these
amendments will only be effective if and when we consummate our tender offer for the Secured Notes.
Our tender offer is scheduled to expire at 12:00 midnight, New York City time, on March 28,
2007, unless extended or earlier terminated.
The total consideration payable in connection with our tender
offer and the consent solicitation for each $1,000 principal amount of our existing notes will be
$1,002.50, plus accrued and unpaid interest to, but not including, the date of payment.
We expect to refinance our Secured Notes with an offering of up to $125 million of new senior
secured notes (New Notes). In connection with our proposed offering of New Notes, we have also
received a firm commitment letter from a national investment banking firm with respect to an alternate
long-term debt financing. In the event our offering of the New Notes is not consummated, we intend
to issue $111 million in debt financing pursuant to this commitment letter in order to refinance our Secured Notes.
We will use the net proceeds of the New Notes (or the debt financing effected pursuant to the
commitment referenced above) to fund amounts payable in connection with the tender offer, the
consent solicitation and to redeem any remaining Secured Notes not repurchased pursuant thereto.
On December 19, 2002, we also established our revolving credit facility, which provides up to
$100 million in revolving credit loans, subject to borrowing base limitations. Our revolving
credit facility has an initial term ending on September 19, 2007. Under our revolving credit
facility, we and Sterling Energy are co-borrowers and are jointly and severally liable for any
indebtedness thereunder. Our revolving credit facility is secured by first priority liens on all
of our accounts receivable, inventory and other specified assets, as well as all of the issued and
outstanding capital stock of Sterling Energy.
Borrowings under our revolving credit facility bear interest, at our option, at an annual rate
of either the Alternate Base Rate plus 0.75% or the LIBO Rate (as defined in our revolving credit
facility) plus 2.75%. The Alternate Base Rate is equal to the greater of the Base Rate as
announced from time to time by JPMorgan Chase Bank in New York, New York, or 0.50% per annum above
the latest Federal Funds Rate (as defined in our revolving credit facility). The average
interest rate for borrowings under our revolving credit facility for the year ended December 31,
2006 was 8.94%. Under our revolving credit facility, we are also required to pay an aggregate
commitment fee of 0.50% per year (payable monthly) on any unused portion. Available credit is
subject to a monthly borrowing base of 85% of eligible accounts receivable plus the lesser of $50
million and 65% of eligible inventory. In addition, the borrowing base for our revolving credit
facility must exceed outstanding borrowings thereunder by $8 million at all times. As of December
31, 2006, total credit available under our revolving credit facility was limited to $72 million due
to these borrowing base limitations. As of December 31, 2006, there were no loans outstanding
under our revolving credit facility, and we had $3 million in letters of credit outstanding.
Our revolving credit facility contains numerous covenants and conditions, including, but not
limited to, restrictions on our ability to incur indebtedness, create liens, sell assets, make
investments, make capital expenditures, engage in mergers and acquisitions and pay dividends. Our
revolving credit facility also contains a covenant that requires us to earn a specified amount of
earnings before interest, income taxes, depreciation and amortization (as defined in our revolving
credit facility) on a monthly basis if, for 15 consecutive days, unused availability under our
revolving credit facility plus cash on hand is less than $20 million. Our revolving credit
facility includes various circumstances and conditions that would, upon their occurrence and
subject in certain cases to notice and grace periods, create an event of default thereunder. In
addition, our revolving credit facility includes both a subjective acceleration clause and a
lock-box arrangement. Based on this, any balances outstanding under our revolving credit facility
are classified as a current portion of long-term debt. We are currently negotiating to amend our
revolving credit facility to extend the term for five years and to make certain other changes to
the borrowing base calculation and interest rates. We expect this amendment to be effective by
March 31, 2007.
Our liquidity (i.e., cash and cash equivalents plus total credit available under our revolving
credit facility) was $90 million as of December 31, 2006, an increase of $4 million compared to our
liquidity as of December 31, 2005. The stated term of our revolving credit facility ends on
September 19, 2007 and our Secured Notes become due on December 19, 2007. As mentioned above, we
have started the process of refinancing the indebtedness under our Secured Notes and amending our
revolving credit facility prior to their stated maturities. Subject to the successful refinancing
of our Secured Notes and amendment of our revolving credit facility, we believe that our cash on
hand,
35
together
with the credit available under our amended revolving credit
facility, is sufficient to meet our short-term and long-term liquidity needs, although our liquidity may not be
adequate during any particular period.
Working Capital
Our working capital, excluding assets and liabilities from discontinued operations, was $90
million as of December 31, 2006, an increase of $12 million from December 31, 2005. This increase
in working capital resulted primarily from an increase in accounts receivable and inventories.
Cash Flow
Net cash used in our operations was $14 million in 2006, compared to net cash provided by our
operations of $68 million in 2005. This reduction in net cash flow in 2006 was primarily driven by
an increase in accounts receivable and inventories.
Net cash flow used in our investing activities was $7 million in 2006 and $10 million in 2005.
Cash flows from investing activities in 2006 included insurance proceeds of $2 million and
proceeds from the sale of fixed assets of $3 million.
There were no net repayments under our revolving credit facility during 2006 compared to $18
million of net repayments in 2005.
Capital Expenditures
Our capital expenditures were $12 million in 2006, $9 million in 2005 and $15 million in 2004.
Capital expenditures are expected to be approximately $15 million in 2007. These capital
expenditures will primarily be for routine safety, environmental and replacement capital.
Our capital expenditures for environmentally related prevention, containment and process
improvements were $2 million in both 2006 and 2005 and we anticipate spending approximately $2
million on these types of expenditures during 2007.
Contractual Cash Obligations
The following table summarizes our significant contractual obligations at December 31, 2006,
and the effect such obligations are expected to have on our liquidity and cash flows in future
periods:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Less than 1 |
|
|
|
|
|
|
|
|
|
More than |
|
|
|
|
year(1) |
|
1-3 years |
|
4-5 years |
|
5 years |
|
Total |
|
|
(Dollars in Thousands) |
Secured Notes |
|
$ |
100,579 |
|
|
$ |
|
|
|
$ |
|
|
|
$ |
|
|
|
$ |
100,579 |
|
Interest payments on debt |
|
|
10,170 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
10,170 |
|
Operating leases |
|
|
293 |
|
|
|
879 |
|
|
|
586 |
|
|
|
220 |
|
|
|
1,978 |
|
Purchase obligations (2) |
|
|
72,000 |
|
|
|
117,000 |
|
|
|
65,000 |
|
|
|
120,000 |
|
|
|
374,000 |
|
Pension and other postretirement
benefits |
|
|
9,675 |
|
|
|
16,717 |
|
|
|
7,230 |
|
|
|
31,113 |
|
|
|
64,735 |
|
Contractual obligations of
discontinued operations |
|
|
217 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
217 |
|
|
|
|
Total |
|
$ |
192,934 |
|
|
$ |
134,596 |
|
|
$ |
72,816 |
|
|
$ |
151,333 |
|
|
$ |
551,679 |
|
|
|
|
|
|
|
(1) |
|
Payment obligations under our revolving credit facility are not presented
because there were no outstanding borrowings as of December 31, 2006, and interest payments
fluctuate depending on the interest rate and outstanding balance under our revolving credit
facility at any point in time. As discussed above, we have started the process of refinancing
the indebtedness under our Secured Notes and our revolving credit facility prior to their
stated maturities. |
|
(2) |
|
For the purposes of this table, we have considered contractual obligations
for the purchase of goods or services as agreements involving more than $1 million that are
enforceable and legally binding and that specify all significant terms, including: fixed or
minimum quantities to be purchased, fixed, minimum or variable price provisions and the |
36
|
|
|
|
|
approximate timing of the transaction. Most of the purchase obligations identified include
variable pricing provisions. We have estimated the future prices of these items, utilizing
forward curves where available. The pricing estimated for use in this table is subject to market
risk. |
Critical Accounting Policies, Use of Estimates and Assumptions
A summary of our significant accounting policies is included in Note 1 of the Notes to
Consolidated Financial Statements included in Item 8, Part II of this Form 10-K. We believe that
the consistent application of these policies enables us to provide readers of our financial
statements with useful and reliable information about our operating results and financial
condition. The following accounting policies are the ones we believe are the most important to the
portrayal of our financial condition and results and require our most difficult, subjective or
complex judgments.
Revenue Recognition
We generally recognize revenue from sales in the open market, raw materials conversion
agreements and long-term supply contracts at the time the products are shipped and title passes.
One of our contractual arrangements includes a profit sharing component, and we estimate and accrue
our expected revenues from this profit sharing arrangement on a monthly basis. Shipping and
handling costs associated with the delivery of our products to customers are included in cost of
goods sold.
Inventories
Inventories are carried at the lower-of-cost-or-market value. Cost is primarily determined on
a first-in, first-out basis, except for stores and supplies, which are valued at average cost. The
comparison of cost to market value involves estimation of the market value of our products. For
the years ended December 31, 2006, 2005 and 2004, this comparison led to a lower-of-cost-or-market
adjustment of zero, $3 million and $16 million, respectively. We enter into agreements with other
companies to exchange chemical inventories in order to minimize working capital requirements and to
facilitate distribution logistics. Balances related to quantities due to or payable by us in
connection with these exchange agreements are included in inventory.
Long-Lived Assets
We assess our long-lived assets for impairment whenever facts and circumstances indicate that
the carrying amount may not be fully recoverable. To analyze recoverability, we project
undiscounted net future cash flows over the remaining book life of these assets. If these
projected cash flows from these assets are less than the carrying amount of these assets, an
impairment would be recognized. Any impairment loss would be measured based upon the difference
between the carrying amount and the fair value of the relevant assets. For these impairment
analyses, recoverability is determined by comparing the estimated fair value of these assets,
utilizing the present value of expected net cash flows, to the carrying value of these assets. In
determining the present value of expected net cash flows, we estimate future net cash flows from
these assets and the timing of those cash flows and then apply a discount rate to reflect the time
value of money and the inherent uncertainty of those future cash flows. The discount rate we use
is based on our estimated cost of capital. The assumptions we use in estimating future cash flows
are consistent with our internal planning. As mentioned above, during 2006, we recorded an
impairment charge of $128 million related to our long-lived styrene assets.
Income Taxes
Deferred income taxes are provided for revenue and expenses which are recognized in different
periods for income tax and financial statement purposes. Deferred tax assets are regularly
assessed for recoverability based on both historical and anticipated earnings levels, and a
valuation allowance is recorded when it is more likely than not that these amounts will not be
recovered. As of December 31, 2006, we had an available U.S. federal income tax net NOL of
approximately $85 million (representing a deferred tax asset of $30 million), which expires during
the years 2023 through 2026. As a result of our analysis, we have concluded that an additional
valuation allowance is needed against our deferred tax assets in the amount of $28 million, which
brings our total valuation allowance to $30 million and results in an overall net deferred tax
asset balance of $4 million. We have also recorded a $4 million liability relating to certain tax
contingencies that we have identified.
37
Employee Benefit Plans
We sponsor domestic defined benefit pension and other postretirement plans. Major assumptions
used in the accounting for these employee benefit plans include the discount rate, expected return
on plan assets and health care cost increase projections. Assumptions are determined based on our
historical data and appropriate market indicators,
and are evaluated each year as of the plans measurement dates. A change in any of these
assumptions would have an effect on net periodic pension and postretirement benefit costs reported
in our financial statements. As mentioned below, in accordance with SFAS No. 158, Employers
Accounting for Defined Benefit Pension and Other Postretirement Plans (SFAS No. 158), we have
recognized the funded status of our defined benefit postretirement plans on our balance sheet and
have provided the required disclosures as of our fiscal year-ended December 31, 2006. We have also
measured the assets and benefit obligations of our defined benefit postretirement plans as of the
date of our fiscal year-end statement of financial position. The effect of the adoption of SFAS
158 was a reduction in our liabilities of $10 million and an increase in stockholders equity, net
of tax, of $7 million.
Plant Turnaround Costs
As a part of normal recurring operations, each of our manufacturing units is completely shut
down from time to time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These periods are
commonly referred to as turnarounds or shutdowns. While actual timing is subject to a number
of variables, turnarounds of our styrene unit typically occur every two to three years. We
currently expense the costs of turnarounds as the associated expenses are incurred. Prior to our
adoption of fresh-start accounting, we had accrued these costs over the expected period between
turnarounds. As expenses for turnarounds can be significant, the impact of expensing turnaround
costs as they are incurred can be material for financial reporting periods during which the
turnarounds actually occur. Turnaround costs expensed during 2006, 2005 and 2004 were $10 million,
$4 million and $12 million, respectively.
New Accounting Standards
In July 2006, the FASB issued FASB Interpretation No. 48, Accounting for Uncertainty in
Income Taxesan interpretation of FASB Statement No. 109, (FIN 48) to clarify the accounting for
uncertain tax positions accounted for in accordance with FASB Statement No. 109, Accounting for
Income Taxes. This interpretation prescribes a two-step approach for recognizing and measuring
tax benefits and requires explicit disclosure of any uncertain tax position. FIN 48 is effective
for us on January 1, 2007. We do not expect the adoption of FIN 48 to have a material impact on
our consolidated financial statements.
Item 7A. Quantitative and Qualitative Disclosures about Market Risk
The table below provides information about our market sensitive financial instruments and
constitutes a forward-looking statement.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fair Value |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
Expected Maturity Dates |
|
2007 |
|
2008 |
|
2009 |
|
2010 |
|
2011 |
|
Thereafter |
|
Total |
|
2006 |
|
|
(Dollars in Thousands) |
Secured Notes |
|
$ |
100,579 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$ |
100,579 |
|
|
$ |
96,125 |
|
Our Secured Notes bear interest at an annual rate of 10%, payable semi-annually on June
15 and December 15 of each year. The fair value of our Secured Notes is based on their quoted
price.
38
Item 8. Financial Statements and Supplementary Data
INDEX TO FINANCIAL STATEMENTS
|
|
|
|
|
Sterling Chemicals, Inc. |
|
|
|
|
|
|
|
|
40 |
|
|
|
|
|
|
|
|
|
41 |
|
|
|
|
|
|
|
|
|
42 |
|
|
|
|
|
|
|
|
|
43 |
|
|
|
|
|
|
|
|
|
44 |
|
|
|
|
|
|
|
|
|
65 |
|
39
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF OPERATIONS
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands, Except Share Data) |
Revenues |
|
$ |
667,544 |
|
|
$ |
641,886 |
|
|
$ |
655,353 |
|
Cost of goods sold |
|
|
654,718 |
|
|
|
653,134 |
|
|
|
633,009 |
|
|
|
|
Gross profit (loss) |
|
|
12,826 |
|
|
|
(11,248 |
) |
|
|
22,344 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Selling, general and administrative expenses |
|
|
9,968 |
|
|
|
7,811 |
|
|
|
11,413 |
|
Impairment of long-lived assets |
|
|
127,653 |
|
|
|
|
|
|
|
48,463 |
|
Gain on pension curtailment |
|
|
|
|
|
|
|
|
|
|
(12,944 |
) |
Gain on sale of methanol plant |
|
|
|
|
|
|
|
|
|
|
(2,396 |
) |
Other expense (income) |
|
|
(15,724 |
) |
|
|
|
|
|
|
|
|
Interest and debt related expenses, net of
interest income |
|
|
10,079 |
|
|
|
10,090 |
|
|
|
10,427 |
|
|
|
|
Loss from continuing operations before
income tax |
|
|
(119,150 |
) |
|
|
(29,149 |
) |
|
|
(32,619 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Provision (benefit) for income taxes |
|
|
(14,488 |
) |
|
|
(10,641 |
) |
|
|
7,262 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing operations |
|
|
(104,662 |
) |
|
|
(18,508 |
) |
|
|
(39,881 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss from discontinued operations, net of tax |
|
|
(997 |
) |
|
|
(11,060 |
) |
|
|
(22,763 |
) |
|
|
|
Net loss |
|
|
(105,659 |
) |
|
|
(29,568 |
) |
|
|
(62,644 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Preferred stock dividends |
|
|
8,205 |
|
|
|
7,014 |
|
|
|
5,994 |
|
|
|
|
Net loss attributable to common stockholders |
|
$ |
(113,864 |
) |
|
$ |
(36,582 |
) |
|
$ |
(68,638 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss per share of common stock, basic and
diluted: |
|
|
|
|
|
|
|
|
|
|
|
|
Loss from continuing operations |
|
$ |
(39.91 |
) |
|
$ |
(9.03 |
) |
|
$ |
(16.24 |
) |
Loss from discontinued operations |
|
|
(0.35 |
) |
|
|
(3.91 |
) |
|
|
(8.06 |
) |
|
|
|
Net loss per share, basic and diluted |
|
$ |
(40.26 |
) |
|
$ |
(12.94 |
) |
|
$ |
(24.30 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted average shares outstanding: |
|
|
|
|
|
|
|
|
|
|
|
|
Basic and diluted |
|
|
2,828,460 |
|
|
|
2,827,795 |
|
|
|
2,825,000 |
|
The accompanying notes are an integral part of the consolidated financial statements.
40
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED BALANCE SHEETS
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
ASSETS |
|
|
|
|
|
|
|
|
Current assets: |
|
|
|
|
|
|
|
|
Cash and cash equivalents |
|
$ |
20,690 |
|
|
$ |
42,197 |
|
Accounts receivable, net of allowance of $1,987 and $953, respectively |
|
|
63,289 |
|
|
|
57,261 |
|
Inventories, net |
|
|
62,078 |
|
|
|
39,094 |
|
Prepaid expenses and other current assets |
|
|
3,215 |
|
|
|
4,888 |
|
Deferred tax asset |
|
|
3,044 |
|
|
|
2,802 |
|
Assets of discontinued operations |
|
|
20 |
|
|
|
1,791 |
|
|
|
|
|
|
|
|
Total current assets |
|
|
152,336 |
|
|
|
148,033 |
|
|
Property, plant and equipment, net |
|
|
83,833 |
|
|
|
230,018 |
|
Other assets, net |
|
|
9,654 |
|
|
|
8,543 |
|
|
|
|
|
|
|
|
Total assets |
|
$ |
245,823 |
|
|
$ |
386,594 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
LIABILITIES AND STOCKHOLDERS EQUITY (DEFICIENCY IN ASSETS) |
|
|
|
|
|
|
|
|
Current liabilities: |
|
|
|
|
|
|
|
|
Accounts payable |
|
$ |
39,123 |
|
|
$ |
43,912 |
|
Accrued liabilities |
|
|
22,872 |
|
|
|
23,690 |
|
Current portion of long-term debt |
|
|
|
|
|
|
|
|
Liabilities of discontinued operations |
|
|
217 |
|
|
|
3,826 |
|
|
|
|
|
|
|
|
Total current liabilities |
|
|
62,212 |
|
|
|
71,428 |
|
|
|
|
|
|
|
|
|
|
Long-term debt |
|
|
100,579 |
|
|
|
100,579 |
|
Deferred income tax liability |
|
|
|
|
|
|
8,196 |
|
Deferred credits and other liabilities |
|
|
49,291 |
|
|
|
77,804 |
|
Redeemable preferred stock |
|
|
56,507 |
|
|
|
48,302 |
|
Commitments and contingencies (Note 9)
|
|
|
|
|
|
|
|
|
Stockholders equity: |
|
|
|
|
|
|
|
|
Common stock, $.01 par value |
|
|
28 |
|
|
|
28 |
|
Additional paid-in capital |
|
|
184,500 |
|
|
|
192,551 |
|
Accumulated deficit |
|
|
(213,614 |
) |
|
|
(107,955 |
) |
Accumulated other comprehensive income (loss) |
|
|
6,320 |
|
|
|
(4,339 |
) |
|
|
|
|
|
|
|
Total stockholders equity (deficiency in assets) |
|
|
(22,766 |
) |
|
|
80,285 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total liabilities and stockholders equity (deficiency in assets) |
|
$ |
245,823 |
|
|
$ |
386,594 |
|
|
|
|
|
|
|
|
The accompanying notes are an integral part of the consolidated financial statements.
41
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF
CHANGES IN STOCKHOLDERS EQUITY (DEFICIENCY IN ASSETS)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accumulated |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Additional |
|
|
|
|
|
|
Other |
|
|
|
|
|
|
Common Stock |
|
|
Paid-In |
|
|
Accumulated |
|
|
Comprehensive |
|
|
|
|
|
|
Shares |
|
|
Amount |
|
|
Capital |
|
|
Deficit |
|
|
Income (Loss) |
|
|
Total |
|
|
|
|
|
|
|
|
|
|
|
(Amounts in Thousands) |
|
|
|
|
|
|
|
|
|
Balance, December 31, 2003 |
|
|
2,825 |
|
|
$ |
28 |
|
|
$ |
205,402 |
|
|
$ |
(15,743 |
) |
|
$ |
(251 |
) |
|
$ |
189,436 |
|
Comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(62,644 |
) |
|
|
|
|
|
|
|
|
Other comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension adjustment |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(715 |
) |
|
|
|
|
Comprehensive loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(63,359 |
) |
Preferred stock dividends |
|
|
|
|
|
|
|
|
|
|
(5,994 |
) |
|
|
|
|
|
|
|
|
|
|
(5,994 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2004 |
|
|
2,825 |
|
|
$ |
28 |
|
|
$ |
199,408 |
|
|
$ |
(78,387 |
) |
|
$ |
(966 |
) |
|
$ |
120,083 |
|
Comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(29,568 |
) |
|
|
|
|
|
|
|
|
Other comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension adjustment |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(3,373 |
) |
|
|
|
|
Comprehensive loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(32,941 |
) |
Preferred stock dividends |
|
|
|
|
|
|
|
|
|
|
(7,014 |
) |
|
|
|
|
|
|
|
|
|
|
(7,014 |
) |
Exercised stock options |
|
|
3 |
|
|
|
|
|
|
|
157 |
|
|
|
|
|
|
|
|
|
|
|
157 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2005 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
192,551 |
|
|
$ |
(107,955 |
) |
|
$ |
(4,339 |
) |
|
$ |
80,285 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(105,659 |
) |
|
|
|
|
|
|
|
|
Other comprehensive loss: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension adjustment |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
3,903 |
|
|
|
|
|
Comprehensive loss |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(101,756 |
) |
SFAS 158 adoption |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
6,756 |
|
|
|
6,756 |
|
Preferred stock dividends |
|
|
|
|
|
|
|
|
|
|
(8,205 |
) |
|
|
|
|
|
|
|
|
|
|
(8,205 |
) |
Stock-based compensation |
|
|
|
|
|
|
|
|
|
|
154 |
|
|
|
|
|
|
|
|
|
|
|
154 |
|
|
|
|
Balance, December 31, 2006 |
|
|
2,828 |
|
|
$ |
28 |
|
|
$ |
184,500 |
|
|
$ |
(213,614 |
) |
|
$ |
6,320 |
|
|
$ |
(22,766 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The accompanying notes are an integral part of the consolidated financial statements.
42
STERLING CHEMICALS, INC. AND SUBSIDIARIES
CONSOLIDATED STATEMENTS OF CASH FLOWS
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands) |
Cash flows from operating activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Net loss |
|
$ |
(105,659 |
) |
|
$ |
(29,568 |
) |
|
$ |
(62,644 |
) |
Adjustments to reconcile net loss to net
cash provided by (used in) operating
activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Depreciation and amortization |
|
|
30,476 |
|
|
|
33,342 |
|
|
|
28,693 |
|
Interest amortization |
|
|
400 |
|
|
|
400 |
|
|
|
398 |
|
Impairment of long-lived assets |
|
|
127,653 |
|
|
|
|
|
|
|
70,498 |
|
Gain on pension curtailment |
|
|
|
|
|
|
|
|
|
|
(12,944 |
) |
Lower-of-cost-or-market adjustment |
|
|
|
|
|
|
2,738 |
|
|
|
16,407 |
|
Deferred tax benefit |
|
|
(8,438 |
) |
|
|
(18,905 |
) |
|
|
(16,529 |
) |
Gain on disposal of property, plant
and equipment |
|
|
(4,917 |
) |
|
|
|
|
|
|
(2,396 |
) |
Other |
|
|
154 |
|
|
|
156 |
|
|
|
1 |
|
Change in assets/liabilities: |
|
|
|
|
|
|
|
|
|
|
|
|
Accounts receivable |
|
|
(5,085 |
) |
|
|
54,850 |
|
|
|
(25,509 |
) |
Inventories |
|
|
(22,608 |
) |
|
|
45,772 |
|
|
|
(42,804 |
) |
Prepaid expenses |
|
|
1,673 |
|
|
|
(690 |
) |
|
|
2,232 |
|
Other assets |
|
|
(2,105 |
) |
|
|
(1,003 |
) |
|
|
(3,650 |
) |
Accounts payable |
|
|
(4,140 |
) |
|
|
(23,348 |
) |
|
|
2,427 |
|
Accrued liabilities |
|
|
(3,758 |
) |
|
|
4,396 |
|
|
|
(1,879 |
) |
Other liabilities |
|
|
(17,854 |
) |
|
|
(33 |
) |
|
|
286 |
|
|
|
|
Net cash provided by (used in) operating
activities |
|
|
(14,208 |
) |
|
|
68,107 |
|
|
|
(47,413 |
) |
|
|
|
Cash flows from investing activities: |
|
|
|
|
|
|
|
|
|
|
|
|
Capital expenditures |
|
|
(11,547 |
) |
|
|
(9,460 |
) |
|
|
(14,771 |
) |
Insurance proceeds relating to
property, plant and equipment |
|
|
1,960 |
|
|
|
|
|
|
|
|
|
Cash used for dismantling |
|
|
(669 |
) |
|
|
(667 |
) |
|
|
|
|
Net proceeds from the sale of fixed
assets assets |
|
|
2,957 |
|
|
|
|
|
|
|
4,017 |
|
|
|
|
Net cash used in investing activities |
|
|
(7,299 |
) |
|
|
(10,127 |
) |
|
|
(10,754 |
) |
|
|
|
Net cash provided by (used in) financing
activities net borrowings (repayments)
under the revolving credit facility |
|
|
|
|
|
|
(17,684 |
) |
|
|
17,684 |
|
|
|
|
Net increase (decrease) in cash |
|
|
(21,507 |
) |
|
|
40,296 |
|
|
|
(40,483 |
) |
Cash and cash equivalents beginning of
period |
|
|
42,197 |
|
|
|
1,901 |
|
|
|
42,384 |
|
|
|
|
Cash and cash equivalents end of year |
|
$ |
20,690 |
|
|
$ |
42,197 |
|
|
$ |
1,901 |
|
|
|
|
Supplement disclosures of cash flow
information: |
|
|
|
|
|
|
|
|
|
|
|
|
Interest paid, net of interest income
received |
|
$ |
10,508 |
|
|
$ |
10,726 |
|
|
$ |
10,957 |
|
Cash paid for income taxes |
|
|
60 |
|
|
|
59 |
|
|
|
50 |
|
The accompanying notes are an integral part of the consolidated financial statements.
43
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
1. BASIS OF PRESENTATION AND SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES
Unless otherwise indicated, references to we, us, our and ours refer collectively to
Sterling Chemicals, Inc. and its wholly-owned subsidiaries. We own or operate facilities at our
petrochemicals complex located in Texas City, Texas, approximately 45 miles south of Houston, on a
290-acre site on Galveston Bay near many other chemical manufacturing complexes and refineries.
Currently, we produce acetic acid, styrene and plasticizers. We own all of the real property which
comprises our Texas City facility and we own the acetic acid, styrene and plasticizers
manufacturing units located at the site. Our Texas City site offers approximately 135 acres for
future expansion by us or by other companies that could benefit from our existing infrastructure
and facilities, and includes a greenbelt around the northern edge of the plant site. We also lease
a portion of our Texas City site to Praxair Hydrogen Supply, Inc. (Praxair), who constructed a
partial oxidation unit on that land, and lease a portion of our Texas City site to S&L Cogeneration
Company, a 50/50 joint venture between us and Praxair Energy Resources, Inc., who constructed a
cogeneration facility on that land. We generally sell our petrochemicals products to customers for
use in the manufacture of other chemicals and products, which in turn are used in the production of
a wide array of consumer goods and industrial products. We operate in one segment,
petrochemicals.
Principles of Consolidation
The consolidated financial statements include the accounts of our wholly-owned subsidiary,
with all significant intercompany accounts and transactions having been eliminated. Our 50% equity
investment in a cogeneration joint venture is not material to our financial position or results of
operations.
Cash and Cash Equivalents
We consider all investments having an initial maturity of three months or less to be cash
equivalents.
Allowance for Doubtful Accounts
Accounts receivable is presented net of allowance for doubtful accounts. We regularly review
our accounts receivable balances and, based on estimated collectibility, adjust the allowance
account accordingly. As of December 31, 2006 and 2005, the allowance for doubtful accounts was $2
million and $1 million, respectively. Bad debt expense (benefit) for 2006, 2005 and 2004, was $1
million, ($2 million) and $0.4 million, respectively.
Inventories
Inventories are stated at the lower-of-cost-or-market. For the years ended December 31, 2006,
2005 and 2004, a lower-of-cost-or-market adjustment was recorded of zero, $3 million and $16
million, respectively. Cost is primarily determined on a first-in, first-out basis, except for
stores and supplies, which are valued at average cost. We enter into agreements with other
companies to exchange chemical inventories in order to minimize working capital requirements and to
facilitate distribution logistics. Balances related to quantities due to or payable by us are
included in inventory.
Property, Plant and Equipment
Property, plant and equipment are recorded at cost. Major renewals and improvements, which
extend the useful lives of equipment, are capitalized. Disposals are removed at carrying cost less
accumulated depreciation with any resulting gain or loss reflected in operations. Depreciation is
provided using the straight-line method over estimated useful lives ranging from five to 25 years,
with the predominant life of plant and equipment being 15 years. We capitalize interest costs,
which are incurred as part of the cost of constructing major facilities and equipment. The amount
of interest capitalized for 2006, 2005 and 2004 was $0.8 million, $1.0 million and $0.9 million,
respectively.
Plant Turnaround Costs
As a part of normal recurring operations, each of our manufacturing units is completely shut
down from time to time, for a period typically lasting two to four weeks, to replace catalysts and
perform major maintenance work required to sustain long-term production. These periods are
commonly referred to as turnarounds or shutdowns. While
44
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
actual timing is subject to a number of variables, turnarounds of our styrene unit typically occur
every two to three years. Costs of turnarounds are expensed as incurred. As expenses for
turnarounds can be significant, the impact of expensing the costs of turnarounds can be material
for financial reporting periods during which the turnarounds actually occur. Turnaround costs
expensed during 2006, 2005 and 2004 were $10 million, $4 million and $12 million, respectively.
Long-Lived Assets
We assess our long-lived assets for impairment whenever facts and circumstances indicate that
the carrying amount may not be fully recoverable. To analyze recoverability, we project
undiscounted net future cash flows over the remaining book life of these assets. If these
projected cash flows from these assets are less than the carrying amount of these assets, an
impairment would be recognized. Any impairment loss would be measured based upon the difference
between the carrying amount and the fair value of the relevant assets. For these impairment
analyses, recoverability is determined by comparing the estimated fair value of these assets,
utilizing the present value of expected net cash flows, to the carrying value of these assets. In
determining the present value of expected net cash flows, we estimate future net cash flows from
these assets and the timing of those cash flows and then apply a discount rate to reflect the time
value of money and the inherent uncertainty of those future cash flows. The discount rate we use
is based on our estimated cost of capital. The assumptions we use in estimating future cash flows
are consistent with our internal planning. During 2006, we recorded a pre-tax impairment charge of
approximately $128 million relating to our long-lived styrene assets.
Debt Issue Costs
Debt issue costs relating to long-term debt are amortized over the term of the related debt
instrument using the straight-line method, which is materially consistent with the effective
interest method, and are included in other assets. Debt issue cost amortization, which is included
in interest and debt-related expenses, was $0.4 million for each of the years ended December 31,
2006, 2005 and 2004.
Income Taxes
Deferred income taxes are provided for revenues and expenses which are recognized in different
periods for income tax and financial statement purposes. Deferred tax assets are regularly
assessed for recoverability based on both historical and anticipated earnings levels, and a
valuation allowance is recorded when it is more likely than not that these amounts will not be
recovered.
Environmental Costs
Environmental costs are expensed as incurred, unless the expenditures extend the economic
useful life of the related assets. Costs that extend the economic life of assets are capitalized
and depreciated over the remaining book life of those assets. Liabilities are recorded when
environmental assessments or remedial efforts are probable and the cost can be reasonably
estimated.
Revenue Recognition
We generate revenues through sales in the open market, raw materials conversion agreements and
long-term supply contracts. In addition, we have entered into profit sharing arrangements with
respect to some of our petrochemicals products. We recognize revenue from sales in the open
market, raw materials conversion agreements and long-term supply contracts when the products are
shipped and title passes. Revenues from profit sharing arrangements are estimated and accrued
monthly. Deferred credits are amortized over the life of the contracts which gave rise to them.
Earnings (Loss) Per Share
Basic earnings per share (EPS) is computed using the weighted-average number of shares
outstanding during the year. Diluted EPS includes common stock equivalents, which are dilutive to
earnings per share. For the years ending December 31, 2006, 2005 and 2004, we had no dilutive
securities outstanding due to all common stock equivalents having an anti-dilutive effect during
these periods.
45
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
Disclosures about Fair Value of Financial Instruments
In preparing disclosures about the fair value of financial instruments, we have assumed that
the carrying amount approximates fair value for cash and cash equivalents, accounts receivable,
accounts payable and certain accrued liabilities due to the short maturities of these instruments.
The fair values of long-term debt instruments are estimated based upon quoted market values (if
applicable) or on the current interest rates available to us for debt with similar terms and
remaining maturities.
Accounting Estimates
The preparation of financial statements in conformity with accounting principles generally
accepted in the United States of America requires management to make estimates and assumptions that
affect the reported amounts of assets and liabilities and disclosure of contingent assets and
liabilities at the date of the financial statements and the reported amounts of revenues and
expenses during the reported periods. Significant estimates include impairment considerations,
allowance for doubtful accounts, inventory valuation, revenue recognition related to profit sharing
accruals, environmental and litigation reserves and provision for income taxes.
2. STOCK-BASED COMPENSATION PLAN
On December 19, 2002, we adopted our 2002 Stock Plan and reserved 379,747 shares of our common
stock for issuance under the plan (subject to adjustment). Under our 2002 Stock Plan, officers and
key employees, as designated by our Board of Directors, may be issued stock options, stock awards,
stock appreciation rights or stock units. There are currently options to purchase a total of
278,500 shares of our common stock outstanding under our 2002 Stock Plan, all at an exercise price
of $31.60, and an additional 85,414 shares of common stock available for issuance under our 2002
Stock Plan.
On January 1, 2006, we adopted Statement of Financial Accounting Standards (SFAS) No.
123-Revised 2004, Share-Based Payments (SFAS No. 123(R)), using the modified prospective
method. SFAS No. 123(R) is a revision of SFAS No. 123, Accounting for Stock-Based Compensation
(SFAS No. 123), and superseded Accounting Principals Board No. 25, Accounting for Stock Issued
to Employees (APB No. 25). Under SFAS No. 123(R), the cost of employee services received in
exchange for a stock-based award is determined based on the grant-date fair value (with limited
exceptions). That cost is then recognized over the period during which the employee is required to
provide services in exchange for the award (usually the vesting period).
On January 1, 2006, using the modified prospective method under SFAS No. 123(R), we began
recognizing expense on any unvested awards under our 2002 Stock Plan that were granted prior to
that time. Any awards granted under our 2002 Stock Plan after December 31, 2005 will be expensed
over the vesting period of the award. Stock based compensation expense was $153,809 for the year
ended December 31, 2006.
Prior to January 1, 2006, we had adopted the disclosure-only provisions of SFAS No. 123 and
accounted for substantially all of our stock-based compensation using the intrinsic value method
prescribed in APB No. 25. Under APB No. 25, no compensation expense was recognized for any of our
stock option grants because all of the stock options issued under our 2002 Stock Plan were granted
with exercise prices at estimated fair value at the time of grant.
46
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
A summary of our stock option activity for the years ended December 31, 2006, 2005 and 2004 is
presented below:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, 2006 |
|
|
December 31, 2005 |
|
|
December 31, 2004 |
|
|
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
Weighted- |
|
|
|
|
|
|
|
average |
|
|
|
|
|
|
average |
|
|
|
|
|
|
average |
|
|
|
Shares |
|
|
exercise price |
|
|
Shares |
|
|
exercise price |
|
|
Shares |
|
|
exercise price |
|
Outstanding at
beginning of year |
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
294,334 |
|
|
$ |
31.60 |
|
|
|
326,000 |
|
|
$ |
31.60 |
|
Granted |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
27,500 |
|
|
|
31.60 |
|
Exercised |
|
|
|
|
|
|
|
|
|
|
(15,834 |
) |
|
|
31.60 |
|
|
|
(59,166 |
) |
|
|
31.60 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Outstanding at end
of year |
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
278,500 |
|
|
$ |
31.60 |
|
|
|
294,334 |
|
|
$ |
31.60 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Options exercisable
at end of year |
|
|
269,333 |
|
|
|
|
|
|
|
176,500 |
|
|
|
|
|
|
|
99,500 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As noted above, no options were granted in 2006 or 2005. The fair value of the grants in 2004
was estimated on the date of grant using the Black-Scholes option pricing model with the following
weighted-average assumptions:
|
|
|
|
|
|
|
2004 |
Expected life (years) |
|
|
10.0 |
|
Expected volatility |
|
|
42.0 |
% |
Expected dividend yield |
|
|
|
|
Risk-free interest rate |
|
|
3.85 |
% |
Weighted-average fair value of options granted during the year |
|
$ |
12.95 |
|
The following table illustrates the effect on our net loss and loss per share attributable to
common stockholders if compensation costs for stock options had been recorded pursuant to SFAS No.
123(R), for the years prior to adoption.
|
|
|
|
|
|
|
|
|
|
|
For the Year Ended December 31, |
|
|
|
2005 |
|
|
2004 |
|
|
|
(Dollars in Thousands, Except Share Data) |
|
Net loss attributable to common stockholders, as reported |
|
$ |
(36,582 |
) |
|
$ |
(68,638 |
) |
|
Add: Stock-based employee compensation expense included in
reported net loss, net of related tax effects |
|
|
157 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deduct: Total stock-based employee compensation expense
determined under fair value based method for all awards,
net of related tax effects |
|
|
(606 |
) |
|
|
(1,147 |
) |
|
|
|
|
|
|
|
Pro forma net loss |
|
$ |
(37,031 |
) |
|
$ |
(69,785 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Loss per share attributable to common stockholders: |
|
|
|
|
|
|
|
|
As reported |
|
$ |
(12.94 |
) |
|
$ |
(24.30 |
) |
Pro forma |
|
|
(13.10 |
) |
|
|
(24.70 |
) |
3. DISCONTINUED OPERATIONS
On September 16, 2005, we announced that we were exiting the acrylonitrile business and
related derivative operations, which included sodium cyanide and disodium iminodiacetic acid
(DSIDA) production, and had been shut down since February 2005. As a result of the exit from
these businesses, we shut down the production facilities and are currently in the process of
dismantling these facilities. Our decision was based on a history of operating losses incurred
47
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
by our acrylonitrile and derivatives businesses, and was made after a full review and analysis of
our strategic alternatives.
In accordance with SFAS No. 144, Accounting for the Impairment and Disposal of Long Lived
Assets, we have reported the operating results of these businesses as discontinued operations in
our consolidated financial statements.
The carrying amounts of the major classes of assets and liabilities related to discontinued
operations as of December 31, 2006 and 2005 were as follows:
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Assets of discontinued operations: |
|
|
|
|
|
|
|
|
Accounts receivable, net |
|
$ |
20 |
|
|
$ |
963 |
|
Inventories |
|
|
|
|
|
|
376 |
|
Other assets |
|
|
|
|
|
|
452 |
|
|
|
|
|
|
|
|
Total |
|
$ |
20 |
|
|
$ |
1,791 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Liabilities of discontinued operations: |
|
|
|
|
|
|
|
|
Accrued liabilities |
|
$ |
217 |
|
|
$ |
3,826 |
|
|
|
|
|
|
|
|
Revenues and pre-tax losses from discontinued operations for the years ended December 31,
2006, 2005 and 2004 are presented below:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands) |
Revenues |
|
$ |
258 |
|
|
$ |
43,374 |
|
|
$ |
196,309 |
|
Loss before income taxes |
|
|
1,135 |
|
|
|
17,420 |
|
|
|
42,025 |
|
Current severance and contractual obligations are detailed below:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued as of |
|
|
|
|
|
|
|
|
|
Accrued as of |
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
|
|
Cash |
|
December 31, |
|
|
Accrued in 2005 |
|
Cash Payments |
|
2005 |
|
Accrued in 2006 |
|
payments |
|
2006 |
|
|
|
Severance accrual |
|
$ |
568 |
|
|
$ |
(91 |
) |
|
$ |
477 |
|
|
$ |
386 |
|
|
$ |
(646 |
) |
|
$ |
217 |
|
DSIDA contractual
obligation |
|
|
2,853 |
|
|
|
|
|
|
|
2,853 |
|
|
|
147 |
|
|
|
(3,000 |
) |
|
|
|
|
DSIDA dismantling costs |
|
|
496 |
|
|
|
|
|
|
|
496 |
|
|
|
62 |
|
|
|
(558 |
) |
|
|
|
|
|
|
|
Totals |
|
$ |
3,917 |
|
|
$ |
(91 |
) |
|
$ |
3,826 |
|
|
$ |
595 |
|
|
$ |
(4,204 |
) |
|
$ |
217 |
|
|
|
|
Prior to our decision to exit the acrylonitrile and derivative businesses, on May 31,
2005, we entered into a Separation Agreement with O&D USA LLC (d/b/a Innovene Chemicals), ANEXCO,
LLC and BP Amoco Chemical Company (BP Chemicals). Under the Separation Agreement:
|
|
|
a prior force majeure dispute among the parties was settled; |
|
|
|
|
most of the acrylonitrile-related agreements between the parties were terminated as of
May 31, 2005, including the Amended and Restated Production Agreement dated March 31, 1998,
the Joint Venture Agreement dated March 31, 1998, the Acrylonitrile Expanded Relationship
and Master Modification Agreement dated June 19, 2003 and the European Distribution
Agreement dated March 31, 1998; |
|
|
|
|
we assigned our interest in ANEXCO, LLC to Innovene Chemicals; and |
|
|
|
|
we and Innovene Chemicals entered into amended and restated versions of our acrylonitrile License
Agreement and Catalyst Sales Contract. |
48
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
In addition, on May 31, 2005, Innovene Chemicals made a one-time payment to us of $0.7 million;
ANEXCO, LLC made an initial distribution to us of $4.8 million and we made a few small payments to
Innovene Chemicals and ANEXCO, LLC for services performed prior to the termination of the
agreements. ANEXCO, LLC made a subsequent distribution to us of $1.5 million on July 15, 2005, and
we received a final distribution of $1.2 million on November 30, 2005. No other payments were or
are required in connection with the settlement of the force majeure dispute or the termination of
the acrylonitrile-related agreements.
4. DETAIL OF CERTAIN BALANCE SHEET ACCOUNTS
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Inventories: |
|
|
|
|
|
|
|
|
Finished products |
|
$ |
38,485 |
|
|
$ |
30,162 |
|
Raw materials |
|
|
17,841 |
|
|
|
7,974 |
|
|
|
|
|
|
|
|
Inventories at lower-of-cost-or-market |
|
|
56,326 |
|
|
|
38,136 |
|
Inventories under exchange agreements |
|
|
1,818 |
|
|
|
(2,807 |
) |
Stores and supplies (net of
obsolescence reserve of $2,149 and
$2,573, respectively) |
|
|
3,934 |
|
|
|
3,765 |
|
|
|
|
|
|
|
|
|
|
$ |
62,078 |
|
|
$ |
39,094 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment, net: |
|
|
|
|
|
|
|
|
Land |
|
$ |
7,149 |
|
|
$ |
7,149 |
|
Buildings |
|
|
4,506 |
|
|
|
4,497 |
|
Plant and equipment |
|
|
306,352 |
|
|
|
286,049 |
|
Construction in progress |
|
|
1,761 |
|
|
|
12,993 |
|
Less: accumulated depreciation |
|
|
(235,935 |
) |
|
|
(80,670 |
) |
|
|
|
|
|
|
|
|
|
$ |
83,833 |
|
|
$ |
230,018 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other assets, net: |
|
|
|
|
|
|
|
|
S&L Cogen joint venture |
|
$ |
4,733 |
|
|
$ |
3,567 |
|
Deferred catalyst |
|
|
1,959 |
|
|
|
2,156 |
|
Long-term deferred tax asset |
|
|
641 |
|
|
|
|
|
Other |
|
|
2,321 |
|
|
|
2,820 |
|
|
|
|
|
|
|
|
|
|
$ |
9,654 |
|
|
$ |
8,543 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued liabilities: |
|
|
|
|
|
|
|
|
Employee compensation and benefits |
|
$ |
13,434 |
|
|
$ |
12,164 |
|
Property taxes |
|
|
4,301 |
|
|
|
5,236 |
|
Other |
|
|
5,137 |
|
|
|
6,290 |
|
|
|
|
|
|
|
|
|
|
$ |
22,872 |
|
|
$ |
23,690 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deferred credits and other liabilities: |
|
|
|
|
|
|
|
|
Accrued postretirement, pension and post employment benefits |
|
$ |
35,596 |
|
|
$ |
62,885 |
|
Deferred revenue |
|
|
8,000 |
|
|
|
9,000 |
|
Other |
|
|
5,695 |
|
|
|
5,919 |
|
|
|
|
|
|
|
|
|
|
$ |
49,291 |
|
|
$ |
77,804 |
|
|
|
|
|
|
|
|
5. VALUATION AND QUALIFYING ACCOUNTS
Below is a summary of valuation and qualifying accounts related to continuing operations for
the years ended December 31, 2006, 2005 and 2004:
49
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
2004 |
|
Allowance for doubtful accounts: |
|
|
|
|
|
|
|
|
|
|
|
|
Balance at beginning of year |
|
$ |
953 |
|
|
$ |
3,092 |
|
|
$ |
2,592 |
|
Add: bad debt expense/(credit) |
|
|
1,049 |
|
|
|
(2,133 |
) |
|
|
500 |
|
Deduct: written-off accounts |
|
|
(15 |
) |
|
|
(6 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at end of year |
|
$ |
1,987 |
|
|
$ |
953 |
|
|
$ |
3,092 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reserve for inventory obsolescence: |
|
|
|
|
|
|
|
|
|
|
|
|
Balance at beginning of year |
|
$ |
2,573 |
|
|
$ |
1,938 |
|
|
$ |
1,370 |
|
Add: obsolescence accrual |
|
|
81 |
|
|
|
1,492 |
|
|
|
969 |
|
Deduct: disposal of inventory |
|
|
(505 |
) |
|
|
(857 |
) |
|
|
(401 |
) |
|
|
|
|
|
|
|
|
|
|
Balance at end of year |
|
$ |
2,149 |
|
|
$ |
2,573 |
|
|
$ |
1,938 |
|
|
|
|
|
|
|
|
|
|
|
6. DEBT
On December 19, 2002, we issued $94.3 million in original principal amount of our 10% Senior
Secured Notes due 2007 (our Secured Notes). Our Secured Notes are senior secured obligations and
rank equally in right of payment with all of our other existing and future senior indebtedness, and
senior in right of payment to all of our existing and future subordinated indebtedness. Our
Secured Notes are guaranteed by Sterling Energy, Inc. (Sterling Energy), our only wholly owned
subsidiary. Sterling Energys guaranty ranks equally in right of payment with all of its existing
and future senior indebtedness, and senior in right of payment to all of its existing and future
subordinated indebtedness. Separate financial information is not presented for Sterling Energy as
it is not material. Our Secured Notes and Sterling Energys guaranty are secured by a first
priority lien on all of our production facilities and related assets.
Our Secured Notes bear interest at an annual rate of 10%, payable semi-annually on June 15 and
December 15 of each year. Until December 19, 2004, we were permitted under certain circumstances
to pay interest on our Secured Notes through the issuance of additional Secured Notes rather than
the payment of cash at an interest rate of 13 3 / 8 % per annum. In December 2003,
we made an interest payment on our Secured Notes at the higher rate through the issuance of $6.3
million in original principal amount of additional Secured Notes, increasing the aggregate
principal amount of outstanding Secured Notes to $100.6 million. We have made all other interest
payments on our Secured Notes in cash. We may redeem our Secured Notes at any time at a redemption
price of 100% of the outstanding principal amount thereof plus accrued and unpaid interest, subject
to compliance with the terms of our revolving credit facility. In addition, in the event of a
specified change of control or the sale of our facility in Texas City, Texas, we are required to
offer to repurchase our Secured Notes at 101% of the outstanding principal amount thereof plus
accrued and unpaid interest. Under certain circumstances, we are also required to use the proceeds
of other asset sales to repurchase those Secured Notes tendered by the holders at a price equal to
100% of the outstanding principal amount thereof plus accrued and unpaid interest.
The indenture governing our Secured Notes contains numerous covenants and conditions,
including, but not limited to, restrictions on our ability to incur indebtedness, create liens,
sell assets, make investments, make capital expenditures, engage in mergers and acquisitions and
pay dividends. The indenture also includes various circumstances and conditions that would, upon
their occurrence and subject in certain cases to notice and grace periods, create an event of
default thereunder. However, the indenture does not require us to satisfy any financial ratios or
maintenance tests.
On March 1, 2007, we commenced an offer to repurchase all of our outstanding Secured Notes
(our tender offer). Concurrently with our tender offer,
we solicited consents from the holders of our Secured Notes to, among other things, eliminate certain
covenants contained in the indenture governing our Secured Notes. The
consent solicitation expired at 5:00 p.m., New York Time, on
March 14, 2007, at which time we received consents
from the requisite principal amount of Secured Notes to amend our indenture. The supplemental indenture we entered into to effect these
amendments will only be effective if and when we consummate our tender offer for the Secured Notes.
Our tender offer is scheduled to expire at 12:00 midnight, New York City time, on March 28,
2007, unless extended or earlier terminated. The total consideration payable in connection with our tender
offer and the consent solicitation for each $1,000 principal amount of our existing notes will be
$1,002.50, plus accrued and unpaid interest to, but not including,
the date of payment.
50
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
We expect to refinance our Secured Notes with an offering of up to $125 million of new senior
secured notes (New Notes). In connection with our proposed offering of New Notes, we have also
received a firm commitment letter from a national investment banking firm with respect to an alternate
long-term debt financing. In the event our offering of the New Notes is not consummated, we intend
to issue $111 million in debt financing pursuant to this
commitment letter in order to refinance our Secured Notes.
We will use the net proceeds of the New Notes (or the debt financing effected pursuant to the
commitment referenced above) to fund amounts payable in connection with the tender offer, the
consent solicitation and to redeem any remaining Secured Notes not repurchased pursuant thereto.
On December 19, 2002, we also established our Revolving Credit Agreement with The CIT
Group/Business Credit, Inc., as administrative agent and a lender, and certain other lenders (our
revolving credit facility), which provides up to $100 million in revolving credit loans, subject
to borrowing base limitations. Our revolving credit facility has an initial term ending on
September 19, 2007. Under our revolving credit facility, we and Sterling Energy are co-borrowers
and are jointly and severally liable for any indebtedness thereunder. Our revolving credit
facility is secured by first priority liens on all of our accounts receivable, inventory and other
specified assets, as well as all of the issued and outstanding capital stock of Sterling Energy.
Borrowings under our revolving credit facility bear interest, at our option, at an annual rate
of either the Alternate Base Rate plus 0.75% or the LIBO Rate (as defined in our revolving credit
facility) plus 2.75%. The Alternate Base Rate is equal to the greater of the Base Rate as
announced from time to time by JPMorgan Chase Bank in New York, New York, or 0.50% per annum above
the latest Federal Funds Rate (as defined in our revolving credit facility). The average
interest rate for borrowings under our revolving credit facility for the year ended December 31,
2006 was 8.94%. Under our revolving credit facility, we are also required to pay an aggregate
commitment fee of 0.50% per year (payable monthly) on any unused portion. Available credit is
subject to a monthly borrowing base of 85% of eligible accounts receivable plus the lesser of $50
million and 65% of eligible inventory. In addition, the borrowing base for our revolving credit
facility must exceed outstanding borrowings thereunder by $8 million at all times. As of December
31, 2006, total credit available under our revolving credit facility was limited to $72 million due
to these borrowing base limitations. As of December 31, 2006, there were no loans outstanding
under our revolving credit facility, and we had $3 million in letters of credit outstanding.
Pursuant to Emerging Issues Task Force Issue No. 95-22, Balance Sheet Classification of Borrowings
under Revolving Credit Agreements That Include both a Subjective Acceleration Clause and a Lock-Box
Arrangement, any balances outstanding under our revolving credit facility are classified as a
current portion of long-term debt. We are currently negotiating to amend our revolving credit
facility to extend the term for five years and to make certain other changes to the borrowing base
calculation and interest rates. We expect this amendment to be effective by March 31, 2007.
The stated term of our revolving credit facility ends on September 19, 2007 and our Secured
Notes become due on December 19, 2007. As mentioned above, we have started the process of
refinancing the indebtedness under our Secured Notes and amending our revolving credit facility
prior to their stated maturities. Subject to the successful refinancing of our Secured Notes and
amendment of our revolving credit facility, we believe that our cash on hand, together with the
credit available under our amended revolving credit facility, is sufficient to meet our
short-term and long-term liquidity needs, although our liquidity may not be adequate during any
particular period.
Debt Maturities
The Secured Notes, which had an aggregate principal balance of $100.6 million outstanding as
of December 31, 2006, are due on December 19, 2007. As a result of the financing arrangement
entered into during March 2007, as discussed above, we have reclassified the debt from current to
long-term as we have the ability and intent to refinance the Secured Notes on a long-term basis.
51
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
7. INCOME TAXES
A reconciliation of federal statutory income taxes to our effective tax benefit is as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
2004 |
|
|
|
(Dollars in Thousands) |
|
Benefit for income taxes at statutory rates |
|
$ |
(42,100 |
) |
|
$ |
(16,299 |
) |
|
$ |
(26,125 |
) |
Non-deductible expenses |
|
|
19 |
|
|
|
19 |
|
|
|
26 |
|
Non-deductible goodwill impairment |
|
|
|
|
|
|
|
|
|
|
16,962 |
|
State income taxes |
|
|
(1,262 |
) |
|
|
(956 |
) |
|
|
(1,933 |
) |
Change in valuation allowance |
|
|
27,621 |
|
|
|
|
|
|
|
|
|
Other |
|
|
1,096 |
|
|
|
235 |
|
|
|
(930 |
) |
|
|
|
|
|
|
|
|
|
|
Effective tax benefit |
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
$ |
(12,000 |
) |
|
|
|
|
|
|
|
|
|
|
The benefit for income taxes is comprised of a tax benefit for continuing operations and a tax
benefit for discontinued operations as shown below:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
2004 |
|
|
|
(Dollars in Thousands) |
|
Tax expense continuing operations |
|
$ |
(14,488 |
) |
|
$ |
(10,641 |
) |
|
$ |
7,262 |
|
Tax expense discontinued operations |
|
|
(138 |
) |
|
|
(6,360 |
) |
|
|
(19,262 |
) |
|
|
|
|
|
|
|
|
|
|
Total tax benefit |
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
$ |
(12,000 |
) |
|
|
|
|
|
|
|
|
|
|
The benefit for income taxes is composed of the following:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
2004 |
|
|
|
(Dollars in Thousands) |
|
Current federal |
|
$ |
299 |
|
|
$ |
|
|
|
$ |
|
|
Deferred federal |
|
|
(13,685 |
) |
|
|
(16,066 |
) |
|
|
(10,105 |
) |
State income taxes |
|
|
(1,240 |
) |
|
|
(935 |
) |
|
|
(1,895 |
) |
|
|
|
|
|
|
|
|
|
|
Total tax benefit |
|
$ |
(14,626 |
) |
|
$ |
(17,001 |
) |
|
$ |
(12,000 |
) |
|
|
|
|
|
|
|
|
|
|
The components of our deferred income tax assets and liabilities are summarized below:
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Deferred tax assets: |
|
|
|
|
|
|
|
|
Accrued liabilities |
|
$ |
1,292 |
|
|
$ |
787 |
|
Accrued postretirement cost |
|
|
7,518 |
|
|
|
12,552 |
|
Accrued pension cost |
|
|
4,537 |
|
|
|
10,770 |
|
Tax loss and credit carry forwards |
|
|
32,506 |
|
|
|
46,734 |
|
State deferred taxes |
|
|
77 |
|
|
|
|
|
Other |
|
|
3,797 |
|
|
|
2,385 |
|
|
|
|
|
|
|
|
Total deferred tax assets |
|
$ |
49,727 |
|
|
$ |
73,228 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Deferred tax liabilities: |
|
|
|
|
|
|
|
|
Property, plant and equipment |
|
$ |
(16,458 |
) |
|
$ |
(66,571 |
) |
State deferred taxes |
|
|
|
|
|
|
(3,219 |
) |
|
|
|
|
|
|
|
Subtotal |
|
|
(16,458 |
) |
|
|
(69,790 |
) |
Less: valuation allowance |
|
|
(29,584 |
) |
|
|
(8,832 |
) |
|
|
|
|
|
|
|
Total deferred tax liabilities |
|
|
(46,042 |
) |
|
|
(78,622 |
) |
|
|
|
|
|
|
|
Net deferred tax assets (liabilities) |
|
$ |
3,685 |
|
|
$ |
(5,394 |
) |
|
|
|
|
|
|
|
52
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
As of December 31, 2006, we had an available U.S. federal income tax net operating loss
carryforward (NOL) of approximately $85 million, which expires during the years 2023 through
2026. Deferred tax assets are regularly assessed for recoverability based on both historical and
anticipated earnings levels, and a valuation allowance is recorded when it is more likely than not
that these amounts will not be recovered. As a result of our analysis, we have concluded that a
valuation allowance should be established in the amount of $28 million relating to our federal
deferred tax assets as of December 31, 2006. At December 31, 2005, we had deferred tax assets
relating to state NOLs of $12 million, which had a related valuation allowance of $9 million.
Under the provisions of the new Texas Margin Tax that was enacted in 2006, these NOLs were
converted into state tax credits of $3 million, $2 million of which relate to pre-bankruptcy items
that we do not believe will be utilized. As such, the valuation allowance relating to these state
deferred tax assets was reduced to $2 million at December 31, 2006. Future recognition of these
items would be recorded as an increase in our paid-in capital under purchase accounting rules
rather than as a reduction in our provision for income taxes. We have also recorded a $4 million
liability relating to certain tax contingencies that we have identified, which has been included in
accrued liabilities.
8. EMPLOYEE BENEFITS
We have established the following benefit plans:
Retirement Benefit Plans
We have non-contributory pension plans which cover all salaried and hourly wage employees.
Under our hourly plan, the benefits are based primarily on years of service and employees pay near
retirement. Under our salaried plan, the benefits are based primarily on years of service and an
employees pay as of the earlier of the employees retirement or January 1, 2005. Our funding
policy is consistent with the funding requirements of federal law and regulations.
Pension plan assets are invested in a balanced portfolio managed by an outside investment
manager. Our investment policy is to generate a total return that, over the long term, provides
sufficient assets to fund its liabilities, reduces risk through diversification of investments
within asset classes and complies with the Employee Retirement Income Security Act of 1974
(ERISA) by investing in a manner consistent with ERISAs fiduciary standards. Within this
balanced fund, assets are invested as follows:
|
|
|
|
|
|
|
|
|
|
|
As of December 31, |
|
|
|
2006 |
|
|
2005 |
|
Equities |
|
|
64 |
% |
|
|
57 |
% |
|
|
|
|
|
|
|
|
|
Bonds |
|
|
23 |
% |
|
|
38 |
% |
|
|
|
|
|
|
|
|
|
Other |
|
|
13 |
% |
|
|
5 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total |
|
|
100 |
% |
|
|
100 |
% |
|
|
|
|
|
|
|
Information concerning the pension obligation, plan assets, amounts recognized in our
financial statements and underlying actuarial assumptions is stated below:
53
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Change in projected benefit obligation: |
|
|
|
|
|
|
|
|
Benefit obligation at beginning of year |
|
$ |
125,694 |
|
|
$ |
119,682 |
|
Service cost |
|
|
593 |
|
|
|
622 |
|
Interest cost |
|
|
7,610 |
|
|
|
6,993 |
|
Actuarial loss |
|
|
820 |
|
|
|
6,259 |
|
Benefits paid |
|
|
(8,582 |
) |
|
|
(7,862 |
) |
|
|
|
|
|
|
|
Benefit obligation at end of year |
|
$ |
126,135 |
|
|
$ |
125,694 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Change in plan assets: |
|
|
|
|
|
|
|
|
Fair value at beginning of year |
|
$ |
95,690 |
|
|
$ |
89,250 |
|
Actual return on plan assets |
|
|
14,684 |
|
|
|
7,643 |
|
Employer contributions |
|
|
7,862 |
|
|
|
6,659 |
|
Benefits paid |
|
|
(8,582 |
) |
|
|
(7,862 |
) |
|
|
|
|
|
|
|
Fair value at end of year |
|
$ |
109,654 |
|
|
$ |
95,690 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reconciliation of amounts recognized: |
|
|
|
|
|
|
|
|
Funded status |
|
$ |
(16,481 |
) |
|
$ |
(30,004 |
) |
Unrecognized actuarial loss |
|
|
|
|
|
|
6,874 |
|
|
|
|
|
|
|
|
Net amount recognized |
|
$ |
(16,481 |
) |
|
$ |
(23,130 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
Amounts recognized in the balance sheet consist of: |
|
|
|
|
|
|
|
|
Current liabilities |
|
$ |
(8,270 |
) |
|
$ |
(7,602 |
) |
Non-current liabilities |
|
|
(8,211 |
) |
|
|
(22,357 |
) |
Accumulated other comprehensive income |
|
|
|
|
|
|
6,829 |
|
|
|
|
|
|
|
|
Net amount recognized in financial position |
|
$ |
(16,481 |
) |
|
$ |
(23,130 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
Amount recognized in accumulated other comprehensive
loss consists of (pre-tax): |
|
|
|
|
Net loss |
|
$ |
(764 |
) |
Prior service costs |
|
|
|
|
|
|
|
|
Net amount recognized in accumulated other comprehensive
loss |
|
$ |
(764 |
) |
|
|
|
|
All plans have projected benefit obligations and accumulated benefit obligation in excess of
plan assets as of December 31, 2006. The total accumulated benefit obligation was $126 million as
of December 31, 2006 and 2005, respectively. Estimated contributions for 2007 are expected to be
approximately $8.5 million, a portion of which are above the minimum funding requirements. The
expected amortization of the actuarial loss for 2007 is $11,000.
Effective as of January 1, 2005, we froze all accruals under our defined benefit pension plan
for our salaried employees, which resulted in a plan curtailment under SFAS No. 88 Employers
Accounting for Settlement and Curtailments of Defined Benefit Pension Plans and for Termination
Benefits. As a result, we recorded a pretax curtailment gain of $13 million in the fourth quarter
of 2004. At the time we froze accruals under our defined benefit pension plan, we also increased
the company match for employee contributions under our 401(k) plan.
54
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
Net periodic pension costs consist of the following components:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars In Thousands) |
Components of net pension costs: |
|
|
|
|
|
|
|
|
|
|
|
|
Service cost-benefits earned during the year |
|
$ |
593 |
|
|
$ |
622 |
|
|
$ |
3,466 |
|
Interest on
prior years projected benefit obligation |
|
|
7,610 |
|
|
|
6,993 |
|
|
|
7,561 |
|
Expected return on plan assets |
|
|
(7,767 |
) |
|
|
(6,641 |
) |
|
|
(5,934 |
) |
Net amortization of actuarial loss (gain) |
|
|
13 |
|
|
|
8 |
|
|
|
|
|
Settlement/curtailment |
|
|
|
|
|
|
|
|
|
|
(12,944 |
) |
|
|
|
Net pension costs |
|
$ |
449 |
|
|
$ |
982 |
|
|
$ |
(7,851 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted-average assumptions: |
|
|
|
|
|
|
|
|
|
|
|
|
Discount Rate |
|
|
5.75 |
% |
|
|
5.75 |
% |
|
|
6.25 |
% |
Rates of increase in salary compensation level |
|
|
3.50 |
% |
|
|
5.00 |
% |
|
|
5.00 |
% |
Expected long-term rate of return on plan assets |
|
|
7.50 |
% |
|
|
7.50 |
% |
|
|
7.50 |
% |
Postretirement Benefits Other than Pensions
We provide certain health care benefits and life insurance benefits for retired employees.
Substantially all of our employees become eligible for these benefits at early retirement age. We
accrue the cost of these benefits during the period in which the employee renders the necessary
service.
Health care benefits are currently provided to employees hired prior to June 7, 2004, who
retire from us with ten or more years of credited service. Some of our employees are eligible for
postretirement life insurance, depending on their hire date. Postretirement health care benefits
plans are contributory. Benefit provisions for most hourly employees are subject to collective
bargaining. In general, retiree health care benefits are paid as covered expenses are incurred.
In September 2005, we recorded a curtailment gain totaling $1.2 million due to workforce
reductions related to our exit from the acrylonitrile and related derivatives businesses. We also
recorded a curtailment gain of $0.5 million attributable to a reduction in our workforce that
occurred in late 2004.
In June 2004, we had a reduction in force at our Texas City plant. This reduction in force
led to a curtailment of our postretirement benefit plan resulting in a $1.4 million curtailment
gain, with $1.3 million of the gain reflected in cost of goods sold and $0.1 million reflected in
selling, general and administrative expenses. In addition, our plan was
amended as of June 1, 2004 as follows: employees hired after this date are not eligible for
retiree medical benefits, our contribution rates for retiree medical coverage are frozen at the
2004 level and prescription drug co-pays were increased. This amendment reduced the accumulated
postretirement benefit obligation by $9.2 million, which is being amortized over the average
remaining service period to full eligibility of the active plan participants (which is 8.5 years).
On December 8, 2003, the Medicare Prescription Drug Improvement and Modernization Act of 2003
(the Act) was passed. The Act introduces a prescription drug benefit under Medicare (Medicare
Part D), as well as a federal subsidy to sponsors of retiree health care benefit plans that provide
a benefit that is at least actuarially equivalent to Medicare Part D. We measured the effects of
the Act on our accumulated postretirement benefit obligation and determined that, based on the
regulatory guidance currently available, benefits provided by our postretirement plan are at least
actuarially equivalent to Medicare Part D, and accordingly, we expect to be entitled to the federal
subsidy through 2009. In 2006, we received a subsidy of $0.2 million under the Act.
Information concerning the plan obligation, the funded status, amounts recognized in our
financial statements and underlying actuarial assumptions are stated below:
55
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
|
2005 |
|
|
|
(Dollars in Thousands) |
|
Change in projected benefit obligation: |
|
|
|
|
|
|
|
|
Benefit obligation at beginning of year |
|
$ |
27,834 |
|
|
$ |
27,745 |
|
Service cost |
|
|
174 |
|
|
|
208 |
|
Interest cost |
|
|
1,463 |
|
|
|
1,558 |
|
Plan amendments |
|
|
|
|
|
|
46 |
|
Actuarial loss (gain) |
|
|
(1,728 |
) |
|
|
1,392 |
|
Benefits paid |
|
|
(1,801 |
) |
|
|
(3,115 |
) |
|
|
|
|
|
|
|
Benefit obligation at end of year |
|
$ |
25,942 |
|
|
$ |
27,834 |
|
|
|
|
|
|
|
|
Funded plan assets |
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Funded status at end of year |
|
$ |
(25,942 |
) |
|
$ |
(27,834 |
) |
Unrecognized cost: |
|
|
|
|
|
|
|
|
Actuarial loss |
|
|
|
|
|
|
6,048 |
|
Plan amendment/prior service cost |
|
|
|
|
|
|
(15,691 |
) |
|
|
|
|
|
|
|
Accrued benefit cost |
|
$ |
(25,942 |
) |
|
$ |
(37,477 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, |
|
|
|
2006 |
|
Amounts recognized in accumulated other
comprehensive income (loss) consist of
(pre-tax): |
|
|
|
|
Net loss |
|
$ |
(3,695 |
) |
Plan amendment/prior service costs |
|
|
14,257 |
|
|
|
|
|
Net amount recognized in accumulated
other comprehensive income (loss) |
|
$ |
(10,562 |
) |
|
|
|
|
Net periodic plan costs consist of the following components:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands) |
Components of net plan costs: |
|
|
|
|
|
|
|
|
|
|
|
|
Service cost |
|
$ |
174 |
|
|
$ |
208 |
|
|
$ |
310 |
|
Interest cost |
|
|
1,463 |
|
|
|
1,558 |
|
|
|
1,864 |
|
Net amortization: |
|
|
|
|
|
|
|
|
|
|
|
|
Actuarial loss |
|
|
99 |
|
|
|
333 |
|
|
|
21 |
|
Plan amendment/prior service costs |
|
|
(1,434 |
) |
|
|
(1,485 |
) |
|
|
(1,223 |
) |
Curtailment and special termination
benefits |
|
|
|
|
|
|
(1,727 |
) |
|
|
(1,418 |
) |
|
|
|
Net plan costs (benefit) |
|
$ |
302 |
|
|
$ |
(1,113 |
) |
|
$ |
(446 |
) |
|
|
|
|
Weighted-average assumptions: |
|
|
|
|
|
|
|
|
|
|
|
|
Discount rate |
|
|
5.75 |
% |
|
|
5.75 |
% |
|
|
5.75 |
% |
The weighted-average annual assumed health care trend rate is assumed to be 9% for 2007. The
rate is assumed to decrease gradually to 4.5% by 2014 and remain level thereafter. Estimated
contributions for 2007 are expected to be approximately $1.4 million. The expected amortization of
the plan amendment prior service costs for 2007 is $1.4 million. Based on plan changes enacted,
assumed health care cost trend rates no longer have a significant effect on the amounts reported
for the health care plans. A one percentage point change in assumed health care trend rates would
have the following effects:
56
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
|
|
|
|
|
|
|
|
|
|
|
1% Increase |
|
1% Decrease |
|
|
(Dollars in Thousands) |
Effect on total of service and interest cost components |
|
$ |
34 |
|
|
$ |
(30 |
) |
Effect on post-retirement benefit obligation |
|
|
619 |
|
|
|
(547 |
) |
In September 2006, the Financial Accounting Standards Board (the FASB) issued SFAS No. 158,
Employers Accounting for Defined Benefit Pension and Other Postretirement Plans (SFAS No.
158). SFAS No. 158 requires the recognition of the funded status of pension and other
postretirement benefit plans on the balance sheet. The overfunded or underfunded status are
recognized as an asset or liability on the balance sheet with changes occurring during the current
year reflected through the comprehensive income portion of equity. SFAS No. 158 also requires the
measurement date of the funded status of our defined benefit postretirement plans match the date of
our fiscal year-end financial statements, eliminating the use of earlier measurement dates that
were previously permissible. We have recognized the funded status of our defined benefit
postretirement plans on our balance sheet and have provided the required disclosures as of our
fiscal year-ended December 31, 2006. We have also measured the assets and benefit obligations of
our defined benefit postretirement plans as of the date of our fiscal year-end statement of
financial position. The incremental effect of applying SFAS No. 158 to our employee benefit plans
as of December 31, 2006 is summarized below (in thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other |
|
|
Pension |
|
postretirement |
|
|
plan |
|
benefits plan |
|
|
|
Increase (decrease) in liabilities |
|
$ |
87 |
|
|
$ |
(10,562 |
) |
Increase (decrease) in accumulated other
comprehensive income |
|
|
(56 |
) |
|
|
6,812 |
|
Increase (decrease) in deferred income
tax liabilities |
|
|
(31 |
) |
|
|
3,750 |
|
Estimated Future Benefits Payable
We estimate that the future benefits payable under our pension and other post-retirement
benefits as of December 31, 2007 are as follows (in thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other |
|
|
|
|
Pensions- |
|
Pensions- |
|
postretirement |
|
|
|
|
hourly |
|
salaried |
|
benefits |
|
Total |
|
|
|
2007 |
|
$ |
3,414 |
|
|
$ |
4,299 |
|
|
$ |
1,275 |
|
|
$ |
8,988 |
|
2008 |
|
|
3,270 |
|
|
|
4,327 |
|
|
|
1,214 |
|
|
|
8,811 |
|
2009 |
|
|
3,158 |
|
|
|
4,449 |
|
|
|
1,178 |
|
|
|
8,785 |
|
2010 |
|
|
2,952 |
|
|
|
4,570 |
|
|
|
2,225 |
|
|
|
9,647 |
|
2011 |
|
|
2,941 |
|
|
|
4,755 |
|
|
|
2,179 |
|
|
|
9,875 |
|
2012-2016 |
|
|
16,361 |
|
|
|
26,204 |
|
|
|
10,567 |
|
|
|
53,132 |
|
|
|
|
Total |
|
$ |
32,096 |
|
|
$ |
48,604 |
|
|
$ |
18,638 |
|
|
$ |
99,238 |
|
|
|
|
Savings and Investment Plan
Our Seventh Amended and Restated Savings and Investment Plan covers substantially all
employees, including executive officers. This Plan is qualified under Section 401(k) of the
Internal Revenue Code. Each participant has the option to defer taxation of a portion of his or
her earnings by directing us to contribute a percentage of such earnings to the Plan. A
participant may direct up to a maximum of 20% of eligible earnings to this Plan, subject to certain
limitations set forth in the Internal Revenue Code. A participants contributions become
distributable upon the termination of his or her employment. Beginning January 1, 2005, we began
matching 100% of salaried employees contributions, to the extent such contributions do not exceed
6% of such participants base compensation (excluding bonuses, profit sharing and similar types of
compensation). Our expense under this plan was $1 million in 2006, $1.1 million in 2005 and $0.8
million in 2004.
57
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
Bonus Plan and Gain Sharing Plan
In February 2002, our Board of Directors, upon recommendation of its Compensation Committee,
approved the establishment of a Bonus Plan and a Gain Sharing Plan. The Bonus Plan is designed to
benefit all qualified salaried employees, while the Gain Sharing Plan is designed to benefit all
qualified hourly employees. Both plans provide our qualified employees the opportunity to earn
bonuses depending on, among other things, our annual financial performance. In January 2006, our
Compensation Committee amended our Bonus Plan in a manner that allows each of our salaried
employees the ability to earn a bonus each year based on their individual performance, irrespective
of our overall financial performance. However, if a bonus is paid for any year based upon our
financial performance, no additional bonus is paid under the new individual performance provision
of the Plan. Our Chief Executive Officer and each of our four Senior Vice Presidents are excluded
from this portion of our Bonus Plan. Whether a bonus will be paid to our Chief Executive Officer
or any of our Senior Vice Presidents in any year when a bonus is not paid based on our financial
performance, and if so, the amount to be paid, will be determined at that time by our Compensation
Committee.
In 2006, after authorization from our Compensation Committee, we accrued $1.4 million pursuant
to this Plan to be paid out no later than March 1, 2007. Although we did not meet the minimum
financial threshold of these plans for 2005, in February 2006, our Compensation Committee
authorized the payment of $725,000 in bonuses based upon our achieving our target goal of $20
million in fixed cost savings during 2005, and we accrued that amount in 2005. In addition,
although we did not meet the minimum financial threshold of these plans for 2004, on February 11,
2005, our Board authorized the payment of $0.9 million in bonuses related to our performance in
2004, and we accrued that amount in 2004.
Key Employee Protection Plan
On January 26, 2000, we instituted our Key Employee Protection Plan, which has subsequently
been amended several times. We established this Plan to help us retain certain of our employees
and motivate them to continue to exert their best efforts on our behalf during periods when we may
be susceptible to a change of control, and to assure their continued dedication and objectivity
during those periods. Our Compensation Committee has designated a select group of management or
highly compensated employees as participants under our Key Employee Protection Plan, and has
established their respective applicable multipliers and other variables for determining benefits.
Our Compensation Committee is also authorized to designate additional management or highly
compensated employees as participants under our Key Employee Protection Plan and set their
applicable multipliers. Our Compensation Committee may also terminate any participants
participation under this Plan with 60 days prior notice if it determines that the participant is
no longer one of our key employees.
Under our Key Employee Protection Plan, any participant under the Plan that terminates his or
her employment for Good Reason or is terminated by us for any reason other than Misconduct or
Disability within his or her Protection Period is entitled to benefits under the Plan. A
participants Protection Period commences 180 days prior to the date on which a specified change of
control occurs and ends either two years or 18 months after the date of that change of control,
depending on the size of the participants applicable multiplier. A participant may also be
entitled to receive payments under this Plan in the absence of a change of control if he or she
terminates his or her employment for Good Reason or is terminated by us for any reason other than
Misconduct or Disability, but in these circumstances his or her applicable multiplier is
reduced by 50%. If a participant becomes entitled to benefits under our Key Employee Protection
Plan, we are required to provide the participant with a lump sum cash payment that is determined by
multiplying the participants applicable multiplier by the sum of the participants highest annual
base compensation during the last three years plus the participants targeted bonus for the year of
termination, and then deducting the sum of any other separation, severance or termination payments
made by us to the participant under any other plan or agreement or pursuant to law.
In addition to the lump sum payment, the participant is entitled to receive any accrued but
unpaid compensation, compensation for unused vacation time and any unpaid vested benefits earned or
accrued under any of our benefit plans (other than qualified plans). Also, for a period of 24
months (including 18 months of COBRA coverage), the participant will continue to be covered by all
of our life, health care, medical and dental insurance plans and programs (other than disability),
as long as the participant makes a timely COBRA election and pays the regular employee premiums
required under our plans and programs and by COBRA. In addition, our obligation to continue to
provide coverage under our
58
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
plans and programs to any participant ends if and when the participant becomes employed on a
full-time basis by a third party which provides the participant with substantially similar
benefits.
If any payment or distribution under our Key Employee Protection Plan to any participant is
subject to excise tax pursuant to Section 4999 of the Internal Revenue Code, the participant is
entitled to receive a gross-up payment from us in an amount such that, after payment by the
participant of all taxes on the gross-up payment, the amount of the gross-up payment remaining is
equal to the excise tax imposed under Section 4999 of the Internal Revenue Code. However, the
maximum amount of any gross-up payment is 25% of the sum of the participants highest annual base
compensation during the last three years plus the participants targeted bonus for the year of
payment.
We may terminate our Key Employee Protection Plan at any time and for any reason but any
termination does not become effective as to any participant until 90 days after we give the
participant notice of the termination of the Plan. In addition, we may amend our Key Employee
Protection Plan at any time and for any reason, but any amendment that reduces, alters, suspends,
impairs or prejudices the rights or benefits of any participant in any material respect does not
become effective as to that participant until 90 days after we give him or her notice of the
amendment of the Plan. No termination of our Key Employee Protection Plan, or any of these types
of amendments to the Plan, can be effective with respect to any participant if the termination or
amendment is related to, in anticipation of or during the pendency of a change of control, is for
the purpose of encouraging or facilitating a change of control or is made within 180 days prior to
any change of control. Finally, no termination or amendment of our Key Employee Protection Plan
can affect the rights or benefits of any participant that are accrued under the Plan at the time of
termination or amendment or that accrue thereafter on account of a change of control that occurred
prior to the termination or amendment or within 180 days after such termination or amendment. We
expensed zero, $0.4 million and $0.3 million in 2006, 2005 and 2004, respectively, pursuant to this
Plan.
Severance Pay Plan
On March 8, 2001, our Board of Directors approved our Severance Pay Plan, which has
subsequently been amended. This Plan covers all of our non-unionized employees and was established
to help us retain these employees by assuring them that they will receive some compensation in the
event that their employment is adversely affected in specified ways. Under our Severance Pay Plan,
any participant that terminates his or her employment for Good Reason or is terminated by us for
any reason other than Misconduct or Disability is entitled to benefits under our Severance Pay
Plan. If a participant becomes entitled to benefits under our Severance Pay Plan, we are required
to provide the participant with a lump sum cash payment in an amount equivalent to two weeks of
such participants base salary for each credited year of service, with a maximum payment of one
years base salary. The amount of this lump sum payment is reduced, however, by the amount of any
other separation, severance or termination payments made by us to the participant under any other
plan or agreement, including our Key Employee Protection Plan, or pursuant to law.
In addition to the lump sum payment, for a period of six months after the participants
termination date, the COBRA premium required to be paid by such participant for coverage under our
medical and dental plans may not be increased beyond that required to be paid by active employees
for similar coverage under those plans, as long as the participant makes a timely COBRA election
and pays the regular employee premiums required under those plans and otherwise continues to be
eligible for coverage under those plans.
We may terminate or amend our Severance Pay Plan at any time and for any reason but no
termination or amendment of our Severance Pay Plan can affect the rights or benefits of any
participant that are accrued under the plan at the time of termination or amendment. We had zero
expense and less than $0.1 million under this Plan in 2006 and 2005, respectively, for continued
operations. In 2004, we expensed $2.4 million under this Plan, with approximately $2 million paid
out in 2005 with the remaining balance yet to be paid.
Due to the exit from our acrylonitrile and derivatives businesses and subsequent workforce
reduction, we expensed $0.4 million in 2006 and $0.5 million in 2005 pursuant to this Plan, of
which $0.7 million has been paid to date, with the balance to be paid in 2007. These amounts are
included in the results from discontinued operations.
59
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
9. COMMITMENTS AND CONTINGENCIES
Product Contracts
We have certain long-term agreements, which provide for the dedication of 100% of our
production of acetic acid and plasticizers, each to one customer. We also have various sales and
conversion agreements, which dedicate significant portions of our production of styrene to various
customers. Some of these agreements generally provide for cost recovery plus an agreed margin or
element of profit based upon market price.
Lease Commitments
We have entered into various non-cancelable long-term operating leases. Future minimum lease
commitments at December 31, 2006, are as follows: 2007 $0.3 million; 2008 $0.3 million; 2009
$0.3 million; 2010 $0.3 million; 2011 $0.3 million and thereafter $0.5 million.
Environmental, Health and Safety
Our operations involve the handling, production, transportation, treatment and disposal of
materials that are classified as hazardous or toxic and that are extensively regulated by
environmental and health and safety laws, regulations and permit requirements. Environmental
permits required for our operations are subject to periodic renewal and may be revoked or modified
for cause or when new or revised environmental requirements are implemented. Changing and
increasingly strict environmental requirements can affect the manufacturing, handling, processing,
distribution and use of our chemical products and, if so affected, our business and operations may
be materially and adversely affected. In addition, changes in environmental requirements may cause
us to incur substantial costs in upgrading or redesigning our facilities and processes, including
our waste treatment, storage, disposal and other waste handling practices and equipment.
Our operating expenditures for environmental matters, mostly waste management and compliance,
were $20 million in both 2006 and 2005. We also spent $2 million for environmentally-related
capital projects in both 2006 and 2005.
Air emissions from our Texas City facility are subject to certain permit requirements and
self-implementing emission limitations and standards under state and federal laws. Our Texas City
facility is located in an area that the Environmental Protection Agency (EPA) has classified as
not having attained the ambient air quality standards for ozone, which is controlled by direct
regulation of volatile organic compounds and nitrogen oxide (NOx) emissions. Our Texas City
facility is also subject to the federal governments June 1997 National Ambient Air Quality
Standards, which lower the ozone and particulate matter concentration thresholds for attainment.
The Texas Commission for Environmental Quality (TCEQ) has imposed strict requirements on
regulated facilities, including our Texas City facility, to ensure that the air quality control
region will achieve the ambient air quality standards for ozone. Local authorities also may impose
new ozone and particulate matter standards. Compliance with these stricter standards may
substantially increase our future NOx, volatile organic compounds and particulate matter emissions
control costs, the amount and full impact of which cannot be determined at this time.
On December 13, 2002, the TCEQ adopted a revised State Implementation Plan (SIP) to achieve
compliance with the 1-hour ozone standard of the Clean Air Act. The EPA approved this 1-hour
SIP, which calls for reduction of emissions of NOx at our Texas City facility by approximately 80%
by the end of 2007. The current 1-hour SIP also requires monitoring of emissions of highly
reactive volatile organic carbons (HRVOCs), such as ethylene. The cost of compliance with the
1-hour SIP at our Texas City facility is estimated to be between $12 million and $14 million.
This estimate includes our share of capital expenditures needed to be made by S&L Cogeneration
Company. To date we have spent $10 million in capital on NOx reductions and HRVOC monitoring, with
$1 million of that amount spent in 2006. In April 2004, the Houston-Galveston region was
designated a moderate non-attainment area with respect to the 8-hour ozone standard of the Clean
Air Act, and compliance with this standard is required no later than June 15, 2010. In December
2006, the TCEQ formally proposed revisions to the SIP in order to achieve compliance with the
8-hour ozone standard. This 8-hour SIP will undergo review and revisions before final adoption
by the TCEQ, which is expected in May 2007, and will then be submitted to the EPA for approval one
month after adoption. The current proposed 8-hour SIP calls for relatively modest additional
controls which we believe
60
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
would require very little expense on our part. However, the proposed package may not receive EPA
approval in its current form, in which case additional controls or monitoring could be added before
the rule becomes finalized. Based on these developments, it is difficult to predict our final cost
of compliance under the 8-hour SIP, but we estimate that the additional cost of compliance will
range from zero to $16 million in capital expenditures and the purchase of allowances, depending on
the terms of the final 8-hour SIP.
To reduce the risk of offsite consequences from unanticipated events, we acquired a greenbelt
buffer zone adjacent to our Texas City facility in 1991. We also participate in a regional air
monitoring network to monitor ambient air quality in the Texas City community.
Legal Proceedings
On July 5, 2005, Patrick B. McCarthy, an employee of Kinder-Morgan, was seriously injured at
Kinder-Morgan, Inc.s facilities near Cincinnati, Ohio while attempting to offload a railcar
containing one of our plasticizers products. On October 28, 2005, Mr. McCarthy and his family
filed a suit in the Court of Common Pleas, Hamilton County, Ohio (Case No. A0509144) against us,
BASF Corporation and five other defendants. The plaintiffs are seeking a minimum amount of
$150,000 in damages related to medical expenses and loss of earnings and earnings capacity, among
other things, and punitive damages. Discovery is ongoing in this case as to the underlying cause
of the accident and the parties respective liabilities, if any. At this time, it is impossible to
determine what, if any, liability we will have for this incident and we will vigorously defend the
suit. We believe that all, or substantially all, of any liability imposed upon us as a result of
this suit and our related out-of-pocket costs and expenses will be covered by our insurance
policies, subject to a $1 million deductible. We do not believe that this incident will have a
material adverse affect on our business, financial position, results of operations or cash flows,
although we cannot guarantee that a material adverse effect will not occur.
On August 17, 2006, we initiated an arbitration proceeding against BP Chemicals to resolve a
dispute involving the interpretation of provisions of our acetic acid production agreement with BP
Chemicals. Under the production agreement, BP Chemicals reimburses our manufacturing expenses and
pays us a percentage of the profits derived from the sales of the acetic acid we produce.
Historically, the costs of manufacturing charged to our acetic acid business, and reimbursed by BP
Chemicals, included the amounts we paid Praxair for carbon monoxide, hydrogen and a blend of carbon
monoxide and hydrogen commonly referred to as blend gas. Our acetic acid business has always
used all of the carbon monoxide produced by Praxair, other than the small amount of carbon monoxide
included in the blend gas. Until recently, all of the blend gas produced by Praxair was used by
the oxo-alcohols plant included in our plasticizers business. During the period when the
oxo-alcohols plant was operating, BP Chemicals was compensated for the use of this blend gas by our
oxo-alcohols plant through a credit to the amount of our manufacturing expenses reimbursed by BP
Chemicals. Effective July 1, 2006, we permanently closed our oxo-alcohols plant. BP Chemicals has
now taken the position that it is entitled to continue to deduct a portion of the blend gas credit
from the reimbursement of our manufacturing expenses, even though our oxo-alcohols plant has been
closed and is no longer taking any blend gas and the Praxair facilities have been modified so that
the carbon monoxide previously used in blend gas is now being delivered to our acetic acid
operations. Effective August 1, 2006, BP Chemicals began short paying our invoices for
manufacturing expenses by the portion of the credit that BP Chemicals claims should continue
through July 31, 2016. The disputed portion of the credit averaged approximately $0.3 million per
month during 2006. We are also seeking additional damages from BP Chemicals in the arbitration
based on what we believe are breaches of duty by BP Chemicals. The arbitration hearing was
scheduled for August 6, 2007. However, pursuant to an agreement reached in principle on January
31, 2007, the parties will abate the arbitration proceeding for a period of at least six months
while they attempt to reach a negotiated settlement. As part of the agreement, BP Chemicals
reimbursed us $0.8 million on February 5, 2007 which was 50% of the accrued disputed credit, and
will continue to pay 50% of the disputed amount each month during the period of negotiation. The
parties have stipulated that the payments are made without prejudice, in that BP Chemicals is not
admitting liability and continues to insist that we remain liable for the disputed portion of the
blend gas credit. According to the agreement, if a settlement is not reached within six months,
either party may reinstate the arbitration process, and seek a hearing date consistent with the
current schedule, or approximately seven months thereafter. Under the January 31, 2007 agreement,
if the arbitration proceeds to an award, the amounts paid by BP Chemicals will be credited against
any sums awarded to us or refunded by us to BP Chemicals, depending on the ruling of the
arbitration panel. We believe that our acetic acid production agreement does not contemplate the
continuation of any portion of the blend gas credit under these circumstances and will vigorously
pursue our position. Although we are in a dispute with BP Chemicals over the interpretation of
this contractual provision, we believe that we
61
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
continue to have a constructive working relationship with BP Chemicals, as has been the case since
1986. As part of the settlement negotiations over the blend gas calculation, we may discuss an
extension of the term of the acetic acid production agreement.
On February 21, 2007, we received a summons naming us as a defendant in a class action suit,
Case No. H-07-0625 filed in the United States District Court, Southern District of Texas, Houston
Division. The plaintiffs comprising the proposed class are employees and retired employees of
Sterling Fibers, Inc., one of our former subsidiaries that was sold in connection with our Plan of
Reorganization. The plaintiffs are alleging that we were not permitted to increase
their premiums for retiree medical insurance based on a provision contained in the asset
purchase agreement between us and Cytec Industries Inc. governing our purchase of our former
acrylic fibers business in 1997. During our bankruptcy, we specifically rejected this asset
purchased agreement. The plaintiffs are making claims for breach of contract and claims under
the Employee Retirement Income Security Act and seek damages, declaratory relief, punitive damages
and attorneys fees. At this time, we have not determined what, if any, liability we may have in
this matter and intend to vigorously defend this action. We do not believe a loss related to this
matter is probable, therefore no liability associated with this matter has been accrued.
Currently, we are unable to determine the possible range of loss related to this matter, if any.
We are subject to various other claims and legal actions that arise in the ordinary course of
our business. We do not believe that any of these claims and actions, separately or in the
aggregate, will have a material adverse effect on our business, financial position, results of
operation or cash flows, although we cannot guarantee that a material adverse effect will not
occur.
10. SALES INFORMATION
Sales by product, sales to major customers constituting 10% or more of total revenues and
export sales from continuing operations were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year ended December 31, |
|
|
2006 |
|
2005 |
|
2004 |
|
|
(Dollars in Thousands) |
Sales by product: |
|
|
|
|
|
|
|
|
|
|
|
|
Acetic acid |
|
$ |
98,344 |
|
|
$ |
86,125 |
|
|
$ |
81,069 |
|
Styrene |
|
|
524,665 |
|
|
|
513,788 |
|
|
|
529,729 |
|
Plasticizers |
|
|
44,535 |
|
|
|
41,973 |
|
|
|
44,555 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Major customers: |
|
|
|
|
|
|
|
|
|
|
|
|
BP Chemicals |
|
$ |
98,344 |
|
|
$ |
86,125 |
|
|
$ |
81,069 |
|
Customer A |
|
|
111,075 |
|
|
|
93,752 |
|
|
|
127,956 |
|
Customer B |
|
|
144,278 |
|
|
|
124,149 |
|
|
|
116,912 |
|
Customer C |
|
|
67,802 |
|
|
|
77,570 |
|
|
|
* |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Export sales: |
|
|
|
|
|
|
|
|
|
|
|
|
Export revenues |
|
$ |
69,926 |
|
|
$ |
143,448 |
|
|
$ |
152,211 |
|
Percentage of total revenues |
|
|
10 |
% |
|
|
22 |
% |
|
|
23 |
% |
|
|
|
* |
|
Does not comprise more than 10% of total revenue for the periods indicated, therefore not
presented. |
11. FINANCIAL INSTRUMENTS
Concentrations of Risk
We sell our products primarily to companies involved in the petrochemicals industry. We
perform ongoing credit evaluations of our customers and generally do not require collateral for
accounts receivable. However, letters of credit are required by us on many of our export sales.
Historically, our credit losses have been minimal.
62
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
We maintain cash deposits with major banks, which from time to time may exceed federally
insured limits. We periodically assess the financial condition of these institutions and believe
that the likelihood of any possible loss is minimal.
Fair Value of Financial Instruments
The carrying amounts reflected in the consolidated balance sheets for cash and cash
equivalents, accounts receivable, accounts payable and certain accrued liabilities approximate fair
value due to the short maturities of these instruments. As of December 31, 2006, the fair value of
our Secured Notes was $96 million based on its quoted price.
12. CAPITAL STOCK
Under our Certificate of Incorporation, we are authorized to issue 20,125,000 shares of
capital stock, consisting of 20,000,000 shares of common stock, par value $0.01 per share, and
125,000 shares of preferred stock, par value $0.01 per share. In connection with our Plan of
Reorganization and the merger of Sterling Chemicals Holdings, Inc. into us, we issued a total of
2,825,000 shares of common stock. Subject to applicable law and the provisions of our Certificate
of Incorporation, the indenture governing our Secured Notes and the revolving credit facility,
dividends may be declared on our shares of capital stock at the discretion of our Board of
Directors and may be paid in cash, in property or in shares of our capital stock.
Upon the effective date of our Plan of Reorganization, we authorized 25,000 shares and issued
2,175 shares of our Series A Convertible Preferred Stock (Series A Preferred Stock). Each share
of Series A Preferred Stock is convertible at the option of the holder thereof at any time into
1,000 shares of our common stock, subject to adjustments. The Series A Preferred Stock has a
cumulative dividend rate of 4% per quarter, payable in additional shares of Series A Preferred
Stock in arrears on the first business day of each calendar quarter. As our shares of Series A
Preferred Stock are convertible into shares of our common stock (currently on a one to 1,000 share
basis), each dividend paid in additional shares of our Series A Preferred Stock has a dilutive
effect on our shares of common stock. Since the initial issuance of Series A Preferred Stock, we
have issued an additional 1,921.760 shares of our Series A Preferred Stock (convertible into
1,921,760 shares of our common stock) in dividends.
Our Series A Preferred Stock carries a liquidation preference of $13,793.11 per share, subject
to adjustments. We may redeem all or any number of our shares of Series A Preferred Stock at any
time after December 19, 2005, at a redemption price determined in accordance with Certificate of
Designations, Preferences, Rights and Limitations of our Series A Preferred Stock, provided that
the current equity value of our capital stock issued on the effective date of our Plan of
Reorganization exceeds specified levels. The holders of our Series A Preferred Stock may elect to
have us redeem all or any of their shares of Series A Preferred Stock following a specified change
of control at a redemption price equal to the greater of:
|
|
|
the liquidation preference for such shares (plus accrued and unpaid dividends); |
|
|
|
|
in the event of a merger or consolidation, the fair market value of the consideration
that would have been received in such merger or consolidation in respect of the shares of
our common stock into which such shares of Series A Preferred Stock were convertible
immediately prior to such merger or consolidation had such shares of Series A Preferred
Stock been converted prior thereto; or |
|
|
|
|
in the event of some other specified change of control, the current market value of the shares of our common stock into which such shares of Series A Preferred Stock were
convertible immediately prior to such change of control had such shares of Series A
Preferred Stock been converted prior thereto (plus accrued and unpaid dividends). |
Upon the effective date of our Plan of Reorganization, we also issued warrants (the
Warrants) to purchase, in the aggregate, 949,367 shares of common stock. Each Warrant represents
the right, at any time on or before December 19, 2008, to purchase one share of our common stock at
an exercise price of $52 per share (subject to adjustments).
63
STERLING CHEMICALS, INC. AND SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS(Continued)
13. RELATED PARTY TRANSACTIONS
Resurgence Asset Management, L.L.C. (Resurgence) has beneficial ownership of a substantial
majority of the voting power of our equity securities due to its investment and disposition
authority over securities owned by its and its affiliates managed funds and accounts. Currently,
Resurgence has beneficial ownership of over 98% of our Series A Preferred Stock and over 60% of our
common stock, representing ownership of over 82% of the total voting power of our equity. Each
share of our Series A Preferred Stock is convertible at the option of the holder thereof at any
time into 1,000 shares of our common stock, subject to adjustments. The holders of our Series A
Preferred Stock are entitled to designate a number of our directors roughly proportionate to their
overall equity ownership, but in any event not less than a majority of our directors as long as
they hold in the aggregate at least 35% of the total voting power of our
equity. As a result, these holders have the ability to control our management, policies and
financing decisions, elect a majority of our Board and control the vote on most matters presented
to a vote of our stockholders. In addition, our shares of Series A Preferred Stock, almost all of
which are beneficially owned by Resurgence, carry a cumulative dividend rate of 4% per quarter,
payable in additional shares of Series A Preferred Stock. Each dividend paid in additional shares
of our Series A Preferred Stock has a dilutive effect on our shares of common stock and increases
the percentage of the total voting power of our equity beneficially owned by Resurgence. Series A
Preferred Stock dividends were 594.832 shares, 508.465 shares and 434.638 shares during 2006, 2005
and 2004, respectively. Four of our directors, Messrs. Steve Gidumal, Byron Haney, Karl
Schwarzfeld and Philip Sivin, are currently employed by Resurgence. Pursuant to established
policies of Resurgence, all director compensation earned by employees of Resurgence is paid
directly to Resurgence. During 2006, 2005 and 2004, we paid Resurgence an aggregate amount equal
to $115,000, $177,500 and $190,750, respectively, related to director compensation for Messrs.
Gidumal, Haney, Schwarzfeld and Sivin, along with reimbursement of an immaterial amount of direct,
out-of-pocket expenses incurred in connection with services as directors. Mr. Gidumal became a
director in November 2006.
14. NEW ACCOUNTING STANDARDS
In July 2006, the FASB issued FASB Interpretation No. 48, Accounting for Uncertainty in
Income Taxesan interpretation of FASB Statement No. 109, (FIN 48) to clarify the accounting for
uncertain tax positions accounted for in accordance with FASB Statement No. 109, Accounting for
Income Taxes. This interpretation prescribes a two-step approach for recognizing and measuring
tax benefits and requires explicit disclosure of any uncertain tax position. FIN 48 is effective
for us on January 1, 2007. We do not expect the adoption of FIN 48 to have a material impact on
our consolidated financial statements.
64
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
To the Board of Directors and Stockholders of Sterling Chemicals, Inc.:
We have audited the accompanying consolidated balance sheets of Sterling Chemicals, Inc. and
its subsidiary (the Company) as of December 31, 2006 and 2005, and the related consolidated
statements of operations, changes in stockholders equity (deficiency in assets), and cash flows
for each of the three years in the period ended December 31, 2006. These financial statements are
the responsibility of the Companys management. Our responsibility is to express an opinion on the
financial statements based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting
Oversight Board (United States). Those standards require that we plan and perform the audit to
obtain reasonable assurance about whether the financial statements are free of material
misstatement. The Company is not required to have, nor were we engaged to perform, an audit of its
internal control over financial reporting. Our audits included consideration of internal control
over financial reporting as a basis for designing audit procedures that are appropriate in the
circumstances, but not for the purpose of expressing an opinion on the effectiveness of the
Companys internal control over financial reporting. Accordingly, we express no such opinion. An
audit also includes examining, on a test basis, evidence supporting the amounts and disclosures in
the financial statements, assessing the accounting principles used and significant estimates made
by management, as well as evaluating the overall financial statement presentation. We believe that
our audits provide a reasonable basis for our opinion.
In our opinion, such consolidated financial statements present fairly, in all material
respects, the financial position of the Company as of December 31, 2006 and 2005, and the results
of its operations and its cash flows for each of the three years in the period ended December 31,
2006, in conformity with accounting principles generally accepted in the United States of America.
As discussed in Note 8 to the Consolidated Financial Statements, the Company changed its
method of accounting for defined benefit pension and other postretirement plans as of December 31,
2006.
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DELOITTE & TOUCHE LLP |
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Houston, Texas |
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March 15, 2007 |
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65
STERLING CHEMICALS, INC.
SUPPLEMENTAL FINANCIAL INFORMATION
QUARTERLY FINANCIAL DATA (unaudited)
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First |
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Second |
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Third |
|
Fourth |
|
|
Year |
|
Quarter |
|
Quarter |
|
Quarter |
|
Quarter |
|
|
(Dollars in Thousands, Except Per Share Data) |
Revenues |
|
|
2006 |
|
|
$ |
136,670 |
|
|
$ |
150,385 |
|
|
$ |
189,916 |
|
|
$ |
190,573 |
|
|
|
|
2005 |
|
|
|
180,207 |
|
|
|
163,515 |
|
|
|
148,733 |
|
|
|
149,431 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gross profit (loss) |
|
|
2006 |
|
|
|
(11,853 |
) |
|
|
5,482 |
|
|
|
13,334 |
|
|
|
5,863 |
|
|
|
|
2005 |
|
|
|
14,370 |
|
|
|
(17,124 |
) |
|
|
4,854 |
|
|
|
(13,348 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from continuing operations (1) |
|
|
2006 |
|
|
|
(9,135 |
) |
|
|
2,137 |
|
|
|
9,949 |
|
|
|
(107,613 |
) |
|
|
|
2005 |
|
|
|
5,645 |
|
|
|
(12,965 |
) |
|
|
115 |
|
|
|
(11,303 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations, net of tax |
|
|
2006 |
|
|
|
(1,254 |
) |
|
|
(496 |
) |
|
|
625 |
|
|
|
128 |
|
|
|
|
2005 |
|
|
|
(3,839 |
) |
|
|
(885 |
) |
|
|
(9,164 |
) |
|
|
2,828 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss) attributable to common stockholders |
|
|
2006 |
|
|
|
(12,321 |
) |
|
|
(368 |
) |
|
|
8,484 |
|
|
|
(109,659 |
) |
|
|
|
2005 |
|
|
|
154 |
|
|
|
(15,569 |
) |
|
|
(10,835 |
) |
|
|
(10,332 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net income (loss) per share of common stock: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic |
|
|
2006 |
|
|
|
(4.36 |
) |
|
|
(0.13 |
) |
|
|
3.00 |
|
|
|
(38.77 |
) |
|
|
|
2005 |
|
|
|
0.05 |
|
|
|
(5.50 |
) |
|
|
(3.83 |
) |
|
|
(3.66 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Diluted |
|
|
2006 |
|
|
|
(4.36 |
) |
|
|
(0.13 |
) |
|
|
1.60 |
|
|
|
(38.77 |
) |
|
|
|
2005 |
|
|
|
0.05 |
|
|
|
(5.50 |
) |
|
|
(3.83 |
) |
|
|
(3.66 |
) |
|
|
|
(1) |
|
In the fourth quarter of 2006, we recorded a $128 million impairment charge to our
styrene assets. |
Item 9. Changes in and Disagreements with Accountants on Accounting and Financial Disclosure
None.
Item 9A. Controls and Procedures
We maintain disclosure controls and procedures that are designed to ensure that
information required to be disclosed in our Exchange Act reports is recorded, processed, summarized
and reported within the time periods specified in the rules and forms of the Securities and
Exchange Commission, and that such information is accumulated and communicated to our management,
including our Chief Executive Officer and Chief Financial Officer, as appropriate, to allow timely
decisions regarding required disclosure. Management necessarily applied its judgment in assessing
the costs and benefits of such controls and procedures which, by their nature, can provide only
reasonable assurance regarding managements control objectives.
We carried out an evaluation, under the supervision and with the participation of our
management, including our Chief Executive Officer and Chief Financial Officer, of the effectiveness
of the design and operation of our disclosure controls and procedures pursuant to Exchange Act Rule
13a-15, as of the end of the fiscal period covered by this Form 10-K. Based upon that evaluation,
each of our Chief Executive Officer and our Chief Financial Officer concluded that our disclosure
controls and procedures are effective in timely alerting them to material information relating to
us (including our consolidated subsidiaries) required to be disclosed in our Exchange Act reports.
In connection with our evaluation, no change was identified in our internal controls over financial
reporting that occurred during the fourth
66
quarter of 2006 that has materially affected, or is reasonably likely to materially affect,
our internal controls over financial reporting.
Beginning with our annual report on Form 10-K for 2007, we will be subject to the provisions
of Section 404 of the Sarbanes-Oxley Act that require an annual management assessment of our
internal controls over financial reporting.
Item 9B. Other Information
In
connection with our expected offering of New Notes described in Managements Discussion and Analysis of Financial Condition and Results of Operations above, we
received on March 14, 2007 a firm commitment letter from
Jefferies & Company, Inc. with respect to an alternate long-term debt financing. In
the event our offering of New Notes is not consummated, we intend to issue $111 million
in debt financing pursuant to this commitment letter in order to
refinance our existing Secured Notes.
67
PART III
Item 10. Directors, Executive Officers and Corporate Governance
Reference is made to the information responsive to Item 10 of this Part III contained in our
definitive proxy statement for our 2007 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 11. Executive Compensation
Reference is made to the information responsive to Item 11 of this Part III contained in our
definitive proxy statement for our 2007 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 12. Security Ownership of Certain Beneficial Owners and Management and Related Stockholder
Matters
Reference is made to the information responsive to Item 12 of this Part III contained in our
definitive proxy statement for our 2007 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 13. Certain Relationships and Related Transactions
Reference is made to the information responsive to Item 13 of this Part III contained in our
definitive proxy statement for our 2007 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
Item 14. Principal Accountant Fees and Services
Reference is made to the information responsive to Item 14 of this Part III contained in our
definitive proxy statement for our 2007 Annual Meeting of Stockholders which is hereby incorporated
herein by reference in response to this item.
68
PART IV
Item 15. Exhibits and Consolidated Financial Statement Schedules
(a) Financial Statements, Financial Statement Schedules and Exhibits.
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1. |
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Consolidated Financial Statements. See Item 8. Financial Statements and
Supplementary Data Index to Financial Statements. |
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2. |
|
Consolidated Financial Statement Schedules. All schedules for which
provision is made in Regulation S-X either are not required under the related
instruction or are inapplicable and, therefore, have been omitted. |
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3. |
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Exhibits. See the Exhibit Index for a list of those exhibits filed herewith,
which index also includes and identifies management contracts or compensatory plans or
arrangements required to be filed as exhibits to this Form 10-K by Item
601(b)(10)(iii) of Regulation S-K. |
(b) Exhibit index.
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Exhibit |
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|
Number |
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|
|
Description of Exhibit |
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2.1
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|
Certificate of Ownership and Merger merging Sterling Chemicals Holdings, Inc.
into Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit 2.1
to our Annual Report on Form 10-K for the fiscal year ended September 30, 2002). |
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2.2
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|
Joint Plan of Reorganization of Sterling Chemicals Holdings, Inc., et. al.,
Debtors, dated October 14, 2002 (incorporated herein by reference from Exhibit
2.1 to our Form 8-K filed on November 26, 2002). |
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2.3
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|
First Modification to Joint Plan of Reorganization of Sterling Chemicals
Holdings, Inc., et. al., Debtors, dated November 18, 2002 (incorporated herein
by reference from Exhibit 2.2 to our Form 8-K filed on November 26, 2002). |
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3.1
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|
Amended and Restated Certificate of Incorporation of Sterling Chemicals, Inc.
(conformed copy) (incorporated herein by reference from Exhibit 3.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended March 31, 2005). |
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3.2
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|
Restated Certificate of Designations, Preferences, Rights and Limitations of
Series A Convertible Preferred Stock of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 3.2 to our Annual Report on Form 10-K for the
fiscal year ended December 31, 2003). |
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3.3
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|
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|
Restated Bylaws of Sterling Chemicals, Inc. (conformed copy) (incorporated
herein by reference from Exhibit 3.3 to our Quarterly Report on Form 10-Q for
the quarterly period ended June 30, 2003). |
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|
4.1
|
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|
Warrant Agreement dated as of December 19, 2002 by and between Sterling
Chemicals, Inc., and Wells Fargo Bank Minnesota, N.A., as warrant agent
(incorporated herein by reference from Exhibit 5 to our Form 8-A filed on
December 19, 2002). |
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4.2
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|
Registration Rights Agreement dated as of December 19, 2002 by and between
Sterling Chemicals, Inc. and Resurgence Asset Management, L.L.C. (incorporated
herein by reference from Exhibit 7 to our Form 8-A filed on December 19, 2002). |
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|
4.3
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|
|
|
Tag Along Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc., Resurgence Asset Management, L.L.C. and the Official Committee
of the Unsecured Creditors (incorporated herein by reference from Exhibit 8 to
our Form 8-A filed on December 19, 2002). |
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|
4.4
|
|
|
|
Indenture dated December 19, 2002 by and among Sterling Chemicals, Inc., as
Issuer, Sterling Chemicals Energy, Inc., as Guarantor, and National City Bank,
as Trustee, governing the 10% Senior Secured Notes due 2007 of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit T3-C to Amendment
No. 3 to our Form T-3 filed on December 19, 2002). |
69
|
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|
Exhibit |
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|
|
Number |
|
|
|
Description of Exhibit |
|
4.5
|
|
|
|
Deed of Trust, Assignment of Leases and Rents, Security Agreement and Fixture
Filing dated December 19, 2002 made by Sterling Chemicals, Inc., as Trustor, to
Thomas S. Henderson, as Individual Trustee for the benefit of National City
Bank, in its capacity as described therein, as Beneficiary (incorporated herein
by reference from Exhibit 4.2 to our Transition Report on Form 10-Q for the
transition period ended December 31, 2002). |
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|
4.6
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|
Security Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Assignors, National City
Bank, as Collateral Agent, and National City Bank, as Indenture Trustee for the
benefit of the holders the 10% Senior Secured Notes due 2007 of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 4.3 to our
Transition Report on Form 10-Q for the transition period ended December 31,
2002). |
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|
10.1
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|
|
|
Revolving Credit Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Borrowers, the various
financial institutions as are or may become parties thereto from time to time,
as the Lenders, and The CIT Group/Business Credit, Inc., as the Administrative
Agent for the Lenders (incorporated herein by reference from Exhibit 4.4 to our
Transition Report on Form 10-Q for the transition period ended December 31,
2002). |
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|
|
|
10.1(a)
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|
|
|
First Amendment to Revolving Credit Agreement dated as of February 12, 2003 by
and among Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc., as
Borrowers, the various financial institutions party thereto, as the Lenders, and
The CIT Group/Business Credit, Inc., as the Administrative Agent for the Lenders
(incorporated herein by reference from Exhibit 4.8 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
|
|
|
|
|
10.2
|
|
|
|
Security Agreement dated as of December 19, 2002 made by Sterling Chemicals,
Inc. and Sterling Chemicals Energy, Inc., as Grantors, in favor of The CIT
Group/Business Credit, Inc., as Administrative Agent for the Secured Parties
(incorporated herein by reference from Exhibit 4.5 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
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|
10.3
|
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|
|
Pledge Agreement dated as of December 19, 2002 made by Sterling Chemicals,
Inc. and Sterling Chemicals Energy, Inc., as Pledgors, in favor of The CIT
Group/Business Credit, Inc., as Administrative Agent for the Secured Parties
(incorporated herein by reference from Exhibit 4.6 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
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|
|
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|
10.4*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated 2002 Stock Plan (incorporated
herein by reference to Exhibit 10.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2006). |
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|
10.5*
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|
|
|
Fifth Amended and Restated Key Employee Protection Plan (incorporated herein
by reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2006). |
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|
10.6*
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Third Amended and Restated Severance Pay Plan (incorporated herein by
reference from Exhibit 10.7 to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2003). |
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10.7*
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Sterling Chemicals, Inc. Amended and Restated Salaried Employees Pension Plan
(incorporated herein by reference from Exhibit 10.3 to our Quarterly Report on
Form 10-Q for the quarterly period ended September 30, 2006). |
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**10.7(a)*
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First Amendment to the Sterling Chemicals, Inc. Amended and Restated Salaried
Employees Pension Plan. |
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10.8*
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Sterling Chemicals, Inc. Pension Benefit Equalization Plan (incorporated
herein by reference from Exhibit 10.10 to our Registration Statement on Form S-1
(Registration No. 33-24020)). |
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10.8(a)*
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First Amendment to Sterling Chemicals, Inc. Pension Benefit Equalization Plan
(incorporated herein by reference from Exhibit 10.9(a) to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2004). |
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10.9*
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Sterling Chemicals, Inc. Amended and Restated Supplemental Employee Retirement
Plan (incorporated herein by reference from Exhibit 10.34 to our Annual Report
on Form 10-K for the fiscal year ended September 30, 1989 (SEC File Number
1-10059)). |
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|
10.9(a)*
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First Amendment to Sterling Chemicals, Inc. Amended and Restated Supplemental
Employee Retirement Plan (incorporated herein by reference from Exhibit 10.10(a)
to our Annual Report on Form 10-K for the fiscal year ended December 31, 2004). |
70
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Exhibit |
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Number |
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|
|
Description of Exhibit |
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10.10
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|
Sterling Chemicals, Inc. Amended and Restated Hourly Paid Employees Pension
Plan (Effective as of May 1, 1996) (incorporated herein by reference from
Exhibit 10.3(c) to our Annual Report on Form 10-K for the fiscal year ended
September 30, 1996 (SEC File Number 333-04343-01)). |
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10.10(a)
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|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of December 31, 1998) (incorporated
herein by reference from Exhibit 10.7(a) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
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10.10(b)
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|
Second Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of December 17, 1998) (incorporated
herein by reference from Exhibit 10.7(b) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
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|
10.10(c)
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|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of September 20, 1999) (incorporated
herein by reference from Exhibit 10.7(c) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
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|
10.10(d)
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|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (incorporated herein by reference from Exhibit 10.4
to our Transition Report on Form 10-Q for the transition period ended December
31, 2002). |
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|
10.10(e)
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|
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|
Fifth Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (incorporated herein by reference from Exhibit 10.5
to our Transition Report on Form 10-Q for the transition period ended December
31, 2002). |
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|
10.10(f)
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|
Sixth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2003). |
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|
10.10(g)
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|
|
|
Seventh Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees
Pension Plan (incorporated herein by reference from Exhibit 10.11(g) to our
Annual Report on Form 10-K for the fiscal year ended December 31, 2003). |
|
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|
|
10.10(h)
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|
|
|
Eighth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees
Pension Plan (incorporated herein by reference from Exhibit 10.3 to our
Quarterly Report on Form 10-Q for the quarterly period ended June 30, 2004). |
|
|
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|
|
10.10(i)
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|
|
|
Ninth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2005). |
|
|
|
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|
10.11*
|
|
|
|
Sterling Chemicals, Inc. Seventh Amended and Restated Savings and Investment
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2006). |
|
|
|
|
|
**10.11(a)*
|
|
|
|
First Amendment to the Seventh Amended and Restated Savings and Investment
Plan. |
|
|
|
|
|
*10.12*
|
|
|
|
Bonus Plan (incorporated herein by reference from Exhibit 10.12 to our Annual
Report on Form 10-K for the fiscal year ended December 31, 2005). |
|
|
|
|
|
10.13
|
|
|
|
Articles of Agreement between Sterling Chemicals, Inc., its successors and
assigns, and Texas City, Texas Metal Trades Council, AFL-CIO Texas City, Texas,
May 27, 2004 to May 1, 2007. (incorporated herein by reference from Exhibit 10.5
to our Quarterly Report on Form 10-Q for the quarterly period ended June 30,
2004). |
|
|
|
|
|
10.14*
|
|
|
|
Form of Indemnity Agreement with each of its officers and directors
(incorporated herein by reference from Exhibit 10.17 to our Annual Report on
Form 10-K for the fiscal year ended September 30, 1996 (SEC File Number
333-04343-01)). |
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|
10.15
|
|
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|
Separation Agreement effective as of May 31, 2005 by and among Sterling
Chemicals, Inc., O&D USA LLC (d/b/a Innovene Chemicals), ANEXCO, LLC and BP
Amoco Chemical Company (incorporated by reference from Exhibit 10.1 to our Form
8-K filed on May 31, 2005). |
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|
|
+10.16
|
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|
|
Second Amended and Restated Production Agreement dated effective as of August
1, 1996 between BP Chemicals Inc. (predecessor in interest to BP Amoco Chemical
Company) and Sterling Chemicals, Inc. (incorporated herein by reference from
Exhibit 10.3 to our Quarterly Report on Form 10-Q for the quarterly period ended
March 31, 1998 (SEC File Number 333-04343-01)). |
71
|
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|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
+10.16(a)
|
|
|
|
Amendment to Second Amended and Restated Production Agreement dated as of
March 1, 2001 between BP Chemicals Inc. (predecessor in interest to BP Amoco
Chemical Company) and Sterling Chemicals, Inc. (incorporated herein by reference
from Exhibit 10.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended March 31, 2001). |
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|
|
++10.16(b)
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|
|
Amendment to Second Amended and Restated Production Agreement dated effective
as of April 1, 2005 between BP Amoco Chemical Company and Sterling Chemicals,
Inc. |
|
|
|
|
|
+10.17
|
|
|
|
Second Amended and Restated Plasticizers Production Agreement dated effective
as of January 1, 2006 between BASF Corporation and Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 10.19 to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2005). |
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|
10.18
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License Agreement dated August 1, 1986 between Monsanto Company and Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 10.25 to our
Registration Statement on Form S-1 (Registration No. 33-24020)). |
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14.1
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|
|
Sterling Chemicals, Inc. Code of Ethics for the Chief Executive Officer and
Senior Financial Officers (incorporated herein by reference from Exhibit 14.1 to
our Quarterly Report on Form 10-Q for the quarterly period ended June 30, 2003). |
|
|
|
|
|
**21.1
|
|
|
|
Subsidiaries of Sterling Chemicals, Inc. |
|
|
|
|
|
**23.1
|
|
|
|
Consent of Deloitte & Touche LLP. |
|
|
|
|
|
**31.1
|
|
|
|
Rule 13a-14(a) Certification of the Chief Executive Officer |
|
|
|
|
|
**31.2
|
|
|
|
Rule 13a-14(a) Certification of the Chief Financial Officer |
|
|
|
|
|
**32.1
|
|
|
|
Section 1350 Certification of the Chief Executive Officer |
|
|
|
|
|
**32.2
|
|
|
|
Section 1350 Certification of the Chief Financial Officer |
|
|
|
|
|
99.1
|
|
|
|
Amended and Restated Audit Committee Charter of Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 99.1 to our Annual Report on Form
10-K for the fiscal year ended December 31, 2005). |
|
|
|
|
|
99.2
|
|
|
|
Amended and Restated Corporate Governance Committee Charter of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 99.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended September 30,
2005). |
|
|
|
|
|
99.3
|
|
|
|
Compensation Committee Charter of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 99.1 to our Quarterly Report on Form 10-Q for
the quarterly period ended September 30, 2006). |
|
|
|
* |
|
Management contracts or compensatory plans or arrangements. |
|
** |
|
Filed or furnished herewith. |
|
+ |
|
Portions of the exhibit have been omitted and filed separately with
the Securities and Exchange Commission pursuant to a request for
confidential treatment.
|
|
++ |
|
Filed herewith. Portions of the exhibit have been omitted and filed
separately with the Securities and Exchange Commission pursuant to a
request for confidential treatment. |
72
SIGNATURES
Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934,
the registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto
duly authorized.
|
|
|
|
|
|
STERLING CHEMICALS, INC.
(Registrant)
|
|
|
By: |
/s/ RICHARD K. CRUMP
|
|
|
|
Richard K. Crump |
|
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President, Chief Executive Officer and Director |
|
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By: |
/s/ PAUL G. VANDERHOVEN
|
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|
Paul G. Vanderhoven |
|
|
|
Senior Vice President-Finance and Chief Financial Officer |
|
|
Date:
March 15, 2007
Pursuant to the requirements of the Securities and Exchange Act of 1934, this report has been
signed below by the following persons on behalf of the registrant and in the capacities and on the
dates indicated.
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Signature |
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Title |
|
Date |
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|
Principal Executive Officer: |
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President, Chief Executive Officer
|
|
March 15, 2007 |
Richard K. Crump
|
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and Director |
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Principal Financial Officer: |
|
|
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|
Senior Vice President-Finance
|
|
March 15, 2007 |
Paul G. Vanderhoven
|
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and Chief Financial Officer |
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|
Principal Accounting Officer: |
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|
|
|
|
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|
Vice President, Corporate Controller
|
|
March 15, 2007 |
John R. Beaver |
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Director
|
|
March 15, 2007 |
Steve L. Gidumal |
|
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Director
|
|
March 15, 2007 |
John W. Gildea |
|
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Director
|
|
March 15, 2007 |
Byron J. Haney |
|
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|
|
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|
|
|
|
|
Director
|
|
March 15, 2007 |
Karl W. Schwarzfeld |
|
|
|
|
|
|
|
|
|
|
|
Director
|
|
March 15, 2007 |
Philip M. Sivin |
|
|
|
|
|
|
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/s/ DR. PETER TING KAI WU
|
|
Director
|
|
March 15, 2007 |
Dr. Peter Ting Kai Wu |
|
|
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|
73
EXHIBIT INDEX
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
|
|
|
|
2.1
|
|
|
|
Certificate of Ownership and Merger merging Sterling Chemicals Holdings, Inc.
into Sterling Chemicals, Inc. (incorporated herein by reference from Exhibit 2.1
to our Annual Report on Form 10-K for the fiscal year ended September 30, 2002). |
|
|
|
|
|
2.2
|
|
|
|
Joint Plan of Reorganization of Sterling Chemicals Holdings, Inc., et. al.,
Debtors, dated October 14, 2002 (incorporated herein by reference from Exhibit
2.1 to our Form 8-K filed on November 26, 2002). |
|
|
|
|
|
2.3
|
|
|
|
First Modification to Joint Plan of Reorganization of Sterling Chemicals
Holdings, Inc., et. al., Debtors, dated November 18, 2002 (incorporated herein
by reference from Exhibit 2.2 to our Form 8-K filed on November 26, 2002). |
|
|
|
|
|
3.1
|
|
|
|
Amended and Restated Certificate of Incorporation of Sterling Chemicals, Inc.
(conformed copy) (incorporated herein by reference from Exhibit 3.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended March 31, 2005). |
|
|
|
|
|
3.2
|
|
|
|
Restated Certificate of Designations, Preferences, Rights and Limitations of
Series A Convertible Preferred Stock of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 3.2 to our Annual Report on Form 10-K for the
fiscal year ended December 31, 2003). |
|
|
|
|
|
3.3
|
|
|
|
Restated Bylaws of Sterling Chemicals, Inc. (conformed copy) (incorporated
herein by reference from Exhibit 3.3 to our Quarterly Report on Form 10-Q for
the quarterly period ended June 30, 2003). |
|
|
|
|
|
4.1
|
|
|
|
Warrant Agreement dated as of December 19, 2002 by and between Sterling
Chemicals, Inc., and Wells Fargo Bank Minnesota, N.A., as warrant agent
(incorporated herein by reference from Exhibit 5 to our Form 8-A filed on
December 19, 2002). |
4.2
|
|
|
|
Registration Rights Agreement dated as of December 19, 2002 by and between
Sterling Chemicals, Inc. and Resurgence Asset Management, L.L.C. (incorporated
herein by reference from Exhibit 7 to our Form 8-A filed on December 19, 2002). |
|
|
|
|
|
4.3
|
|
|
|
Tag Along Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc., Resurgence Asset Management, L.L.C. and the Official Committee
of the Unsecured Creditors (incorporated herein by reference from Exhibit 8 to
our Form 8-A filed on December 19, 2002). |
|
|
|
|
|
4.4
|
|
|
|
Indenture dated December 19, 2002 by and among Sterling Chemicals, Inc., as
Issuer, Sterling Chemicals Energy, Inc., as Guarantor, and National City Bank,
as Trustee, governing the 10% Senior Secured Notes due 2007 of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit T3-C to Amendment
No. 3 to our Form T-3 filed on December 19, 2002). |
|
|
|
|
|
4.5
|
|
|
|
Deed of Trust, Assignment of Leases and Rents, Security Agreement and Fixture
Filing dated December 19, 2002 made by Sterling Chemicals, Inc., as Trustor, to
Thomas S. Henderson, as Individual Trustee for the benefit of National City
Bank, in its capacity as described therein, as Beneficiary (incorporated herein
by reference from Exhibit 4.2 to our Transition Report on Form 10-Q for the
transition period ended December 31, 2002). |
|
|
|
|
|
4.6
|
|
|
|
Security Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Assignors, National City
Bank, as Collateral Agent, and National City Bank, as Indenture Trustee for the
benefit of the holders the 10% Senior Secured Notes due 2007 of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 4.3 to our
Transition Report on Form 10-Q for the transition period ended December 31,
2002). |
|
|
|
|
|
10.1
|
|
|
|
Revolving Credit Agreement dated as of December 19, 2002 by and among Sterling
Chemicals, Inc. and Sterling Chemicals Energy, Inc., as Borrowers, the various
financial institutions as are or may become parties thereto from time to time,
as the Lenders, and The CIT Group/Business Credit, Inc., as the Administrative
Agent for the Lenders (incorporated herein by reference from Exhibit 4.4 to our
Transition Report on Form 10-Q for the transition period ended December 31,
2002). |
74
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
10.1(a)
|
|
|
|
First Amendment to Revolving Credit Agreement dated as of February 12, 2003 by
and among Sterling Chemicals, Inc. and Sterling Chemicals Energy, Inc., as
Borrowers, the various financial institutions party thereto, as the Lenders, and
The CIT Group/Business Credit, Inc., as the Administrative Agent for the Lenders
(incorporated herein by reference from Exhibit 4.8 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
|
|
|
|
|
10.2
|
|
|
|
Security Agreement dated as of December 19, 2002 made by Sterling Chemicals,
Inc. and Sterling Chemicals Energy, Inc., as Grantors, in favor of The CIT
Group/Business Credit, Inc., as Administrative Agent for the Secured Parties
(incorporated herein by reference from Exhibit 4.5 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
|
|
|
|
|
10.3
|
|
|
|
Pledge Agreement dated as of December 19, 2002 made by Sterling Chemicals,
Inc. and Sterling Chemicals Energy, Inc., as Pledgors, in favor of The CIT
Group/Business Credit, Inc., as Administrative Agent for the Secured Parties
(incorporated herein by reference from Exhibit 4.6 to our Transition Report on
Form 10-Q for the transition period ended December 31, 2002). |
|
|
|
|
|
10.4*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated 2002 Stock Plan (incorporated
herein by reference to Exhibit 10.1 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2006). |
|
|
|
|
|
10.5*
|
|
|
|
Fifth Amended and Restated Key Employee Protection Plan (incorporated herein
by reference from Exhibit 10.2 to our Quarterly Report on Form 10-Q for the
quarterly period ended September 30, 2006). |
|
|
|
|
|
10.6*
|
|
|
|
Third Amended and Restated Severance Pay Plan (incorporated herein by
reference from Exhibit 10.7 to our Annual Report on Form 10-K for the fiscal
year ended December 31, 2003). |
|
|
|
|
|
10.7*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Salaried Employees Pension Plan
(incorporated herein by reference from Exhibit 10.3 to our Quarterly Report on
Form 10-Q for the quarterly period ended September 30, 2006). |
|
|
|
|
|
**10.7(a)*
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated Salaried
Employees Pension Plan. |
|
|
|
|
|
10.8*
|
|
|
|
Sterling Chemicals, Inc. Pension Benefit Equalization Plan (incorporated
herein by reference from Exhibit 10.10 to our Registration Statement on Form S-1
(Registration No. 33-24020)). |
|
|
|
|
|
10.8(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Pension Benefit Equalization Plan
(incorporated herein by reference from Exhibit 10.9(a) to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2004). |
|
|
|
|
|
10.9*
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Supplemental Employee Retirement
Plan (incorporated herein by reference from Exhibit 10.34 to our Annual Report
on Form 10-K for the fiscal year ended September 30, 1989 (SEC File Number
1-10059)). |
|
|
|
|
|
10.9(a)*
|
|
|
|
First Amendment to Sterling Chemicals, Inc. Amended and Restated Supplemental
Employee Retirement Plan (incorporated herein by reference from Exhibit 10.10(a)
to our Annual Report on Form 10-K for the fiscal year ended December 31, 2004). |
|
|
|
|
|
10.10
|
|
|
|
Sterling Chemicals, Inc. Amended and Restated Hourly Paid Employees Pension
Plan (Effective as of May 1, 1996) (incorporated herein by reference from
Exhibit 10.3(c) to our Annual Report on Form 10-K for the fiscal year ended
September 30, 1996 (SEC File Number 333-04343-01)). |
|
|
|
|
|
10.10(a)
|
|
|
|
First Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of December 31, 1998) (incorporated
herein by reference from Exhibit 10.7(a) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
|
|
|
|
|
10.10(b)
|
|
|
|
Second Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of December 17, 1998) (incorporated
herein by reference from Exhibit 10.7(b) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
|
|
|
|
|
10.10(c)
|
|
|
|
Third Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (Effective as of September 20, 1999) (incorporated
herein by reference from Exhibit 10.7(c) to our Annual Report on Form 10-K for
the fiscal year ended September 30, 2000). |
75
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
10.10(d)
|
|
|
|
Fourth Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (incorporated herein by reference from Exhibit 10.4
to our Transition Report on Form 10-Q for the transition period ended December
31, 2002). |
10.10(e)
|
|
|
|
Fifth Amendment to the Sterling Chemicals, Inc. Amended and Restated Hourly
Paid Employees Pension Plan (incorporated herein by reference from Exhibit 10.5
to our Transition Report on Form 10-Q for the transition period ended December
31, 2002). |
|
|
|
|
|
10.10(f)
|
|
|
|
Sixth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2003). |
|
|
|
|
|
10.10(g)
|
|
|
|
Seventh Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees
Pension Plan (incorporated herein by reference from Exhibit 10.11(g) to our
Annual Report on Form 10-K for the fiscal year ended December 31, 2003). |
|
|
|
|
|
10.10(h)
|
|
|
|
Eighth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees
Pension Plan (incorporated herein by reference from Exhibit 10.3 to our
Quarterly Report on Form 10-Q for the quarterly period ended June 30, 2004). |
10.10(i)
|
|
|
|
Ninth Amendment to the Sterling Chemicals, Inc. Hourly Paid Employees Pension
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2005). |
10.11*
|
|
|
|
Sterling Chemicals, Inc. Seventh Amended and Restated Savings and Investment
Plan (incorporated herein by reference from Exhibit 10.3 to our Quarterly Report
on Form 10-Q for the quarterly period ended June 30, 2006). |
**10.11(a)*
|
|
|
|
First Amendment to the Seventh Amended and Restated Savings and Investment
Plan. |
|
|
|
|
|
*10.12*
|
|
|
|
Bonus Plan (incorporated herein by reference from Exhibit 10.12 to our Annual
Report on Form 10-K for the fiscal year ended December 31, 2005). |
|
|
|
|
|
10.13
|
|
|
|
Articles of Agreement between Sterling Chemicals, Inc., its successors and
assigns, and Texas City, Texas Metal Trades Council, AFL-CIO Texas City, Texas,
May 27, 2004 to May 1, 2007. (incorporated herein by reference from Exhibit 10.5
to our Quarterly Report on Form 10-Q for the quarterly period ended June 30,
2004). |
|
|
|
|
|
10.14*
|
|
|
|
Form of Indemnity Agreement with each of its officers and directors
(incorporated herein by reference from Exhibit 10.17 to our Annual Report on
Form 10-K for the fiscal year ended September 30, 1996 (SEC File Number
333-04343-01)). |
|
|
|
|
|
10.15
|
|
|
|
Separation Agreement effective as of May 31, 2005 by and among Sterling
Chemicals, Inc., O&D USA LLC (d/b/a Innovene Chemicals), ANEXCO, LLC and BP
Amoco Chemical Company (incorporated by reference from Exhibit 10.1 to our Form
8-K filed on May 31, 2005). |
|
|
|
|
|
+10.16
|
|
|
|
Second Amended and Restated Production Agreement dated effective as of August
1, 1996 between BP Chemicals Inc. (predecessor in interest to BP Amoco Chemical
Company) and Sterling Chemicals, Inc. (incorporated herein by reference from
Exhibit 10.3 to our Quarterly Report on Form 10-Q for the quarterly period ended
March 31, 1998 (SEC File Number 333-04343-01)). |
|
|
|
|
|
+10.16(a)
|
|
|
|
Amendment to Second Amended and Restated Production Agreement dated as of
March 1, 2001 between BP Chemicals Inc. (predecessor in interest to BP Amoco
Chemical Company) and Sterling Chemicals, Inc. (incorporated herein by reference
from Exhibit 10.1 to our Quarterly Report on Form 10-Q for the quarterly period
ended March 31, 2001). |
|
|
|
|
|
++10.16(b)
|
|
|
|
Amendment to Second Amended and Restated Production Agreement dated effective
as of April 1, 2005 between BP Amoco Chemical Company and Sterling Chemicals,
Inc. |
|
|
|
|
|
+10.17
|
|
|
|
Second Amended and Restated Plasticizers Production Agreement dated effective
as of January 1, 2006 between BASF Corporation and Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 10.19 to our Annual Report on
Form 10-K for the fiscal year ended December 31, 2005). |
|
|
|
|
|
10.18
|
|
|
|
License Agreement dated August 1, 1986 between Monsanto Company and Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 10.25 to our
Registration Statement on Form S-1 (Registration No. 33-24020)). |
76
|
|
|
|
|
Exhibit |
|
|
|
|
Number |
|
|
|
Description of Exhibit |
|
14.1
|
|
|
|
Sterling Chemicals, Inc. Code of Ethics for the Chief Executive Officer and
Senior Financial Officers (incorporated herein by reference from Exhibit 14.1 to
our Quarterly Report on Form 10-Q for the quarterly period ended June 30, 2003). |
|
|
|
|
|
**21.1
|
|
|
|
Subsidiaries of Sterling Chemicals, Inc. |
|
|
|
|
|
**23.1
|
|
|
|
Consent of Deloitte & Touche LLP. |
|
|
|
|
|
**31.1
|
|
|
|
Rule 13a-14(a) Certification of the Chief Executive Officer |
|
|
|
|
|
**31.2
|
|
|
|
Rule 13a-14(a) Certification of the Chief Financial Officer |
|
|
|
|
|
**32.1
|
|
|
|
Section 1350 Certification of the Chief Executive Officer |
|
|
|
|
|
**32.2
|
|
|
|
Section 1350 Certification of the Chief Financial Officer |
|
|
|
|
|
99.1
|
|
|
|
Amended and Restated Audit Committee Charter of Sterling Chemicals, Inc.
(incorporated herein by reference from Exhibit 99.1 to our Annual Report on Form
10-K for the fiscal year ended December 31, 2005). |
|
|
|
|
|
99.2
|
|
|
|
Amended and Restated Corporate Governance Committee Charter of Sterling
Chemicals, Inc. (incorporated herein by reference from Exhibit 99.1 to our
Quarterly Report on Form 10-Q for the quarterly period ended September 30,
2005). |
|
|
|
|
|
99.3
|
|
|
|
Compensation Committee Charter of Sterling Chemicals, Inc. (incorporated
herein by reference from Exhibit 99.1 to our Quarterly Report on Form 10-Q for
the quarterly period ended September 30, 2006). |
|
|
|
* |
|
Management contracts or compensatory plans or arrangements. |
|
** |
|
Filed or furnished herewith. |
|
+ |
|
Portions of the exhibit have been omitted and filed separately with
the Securities and Exchange Commission pursuant to a request for
confidential treatment. |
|
++ |
|
Filed herewith. Portions of the exhibit have been omitted and filed
separately with the Securities and Exchange Commission pursuant to a
request for confidential treatment. |
77